Automotive

Breaking Down the High-Tech Design Behind Vehicle Suspension System

Driving without a suspension system can be very uncomfortable and bumpy. The suspension is the ultimate wingman for your car. The suspension system is a network of components in your vehicle designed to absorb and manage the impact of forces generated while driving. In simple words, it ensures that your ride is smooth and controlled.

This article will provide deep insights into suspension systems and their role in driving dynamics by breaking down their functions step by step.

How Suspension System Works

Your car’s suspension system is like a symphony orchestra. The springs are like the strings, adding a soft melody to the road bumps. Shock absorbers act as the conductors, making sure every note is played with perfection. The control arms and links are skillful musicians, creating a harmonious ride that’s music to your ears.

Your car’s suspension system operates through a combination of components to provide a comfortable and stable ride. At its core are springs designed to absorb the impact of bumps and road irregularities. When the wheels encounter such obstacles, the springs compress, store energy, and release it to minimize the harsh effect.

Completing the springs are shock absorbers responsible for dampening the changes created by the bouncing motion of the springs. These absorbers make sure a controlled and smooth ride by regulating the movement of the springs.

Control arms and links connect the wheels to the vehicle’s body, allowing for coordinated activity during turns and braking. The collaborative function of these components results in a suspension system that increases the vehicle’s comfort and handling, providing a balanced and enjoyable driving experience.

In short, suspension system elements such as springs, shock absorbers, struts, and various linkages help maintain the tire contact with the road and stabilize the vehicle during navigation. The system is designed to balance the weight distribution, minimize vibrations and impacts, and adapt to varying road conditions.

Breaking Down the Suspension System

The suspension system is comprised of many interconnected components. You can see the breakdown below.

Vehicle Suspension System

Figure: Close-up of a car’s suspension system

Springs:

Springs are crucial to the suspension system of your car; they function as shock absorbers and provide cushioning, especially when the vehicle is on uneven terrain or a bumpy road. When the wheels of your car come across a barrier., the springs compress to absorb the impact energy. Later, they release this stored energy, preventing the vehicle from bouncing uncontrollably. Crafted with precision and efficiency by advanced manufacturing techniques like CNC machining, springs play a critical role in automotive engineering due to their ability to absorb shocks, maintain tire contact, and influence handling.

Shock Absorbers:

Shock absorbers complete the action of springs by controlling the movements and preventing extreme bouncing. What happens is that When the springs compress and release, shock absorbers damp the movement by using hydraulic or gas means. This controlled motion guarantees a smooth ride for you.

Control Arms and Links:

Control arms and links connect your car’s body to the wheels, allowing controlled movement during turns and braking. These components shift and move in response to steering and braking inputs. Make sure that your wheels are aligned and your vehicle is stable. In this component, ball joints also play an unassuming yet key role.

These spherical joints at the ends of control arms act as pivots, allowing the wheels to move up and down while maintaining a connection to the suspension system. Their smooth operation is essential for a smooth and controlled ride. The stabilizer bar, also known as an anti-roll bar, also plays the role of a balance master. This component, typically a long, torsion-resistant bar, connects the suspension components on opposite sides of the vehicle, working to minimize body roll during cornering.

Types of Suspension Systems

There are several types of suspension systems used in vehicles, each designed to fulfil specific needs related to comfort, handling, and stability. Let’s discuss them in detail.

Vehicle Suspension System

Figure: Types of Suspension Systems

Independent Suspension:

Independent Suspension can be further divided into subtypes to understand its mechanism better.

Double Wishbone Suspension: Uses two parallel wishbone-shaped arms resembling the letter “A”. Thanks to these arms, each wheel can move up and down independently when you hit a bump. This design offers better handling because it allows each wheel to respond to the road conditions individually.

Multi-Link Suspension: It is more of a sophisticated network of multiple links and control arms. It is like a system of interconnected levers supporting your car’s wheels. They are more precise and make sure that your ride is responsive.

Dependent Suspension:

This also can be further divided into

Solid Axle Suspension: Connects both wheels on an axle, and the movement of one wheel affects the other. It’s simpler but may offer you a rougher ride compared to independent systems.

Torsion Beam Suspension: A simpler version of independent Suspension, often used in rear-wheel-drive vehicles.

Air Suspension:

This suspension type Uses air springs instead of traditional coil or leaf springs. It allows for adjustable ride height and a smoother ride; if you own a luxury vehicle or SUV, you probably have this type of suspension.

MacPherson Strut Suspension:

This type of suspension is often found in front-wheel-drive cars; it is a straightforward approach to suspension design. It merges a coil spring and a shock absorber into a single unit, making it simpler. This setup is then placed in each front of your car’s wheel assembly, simplifying the overall structure of the front suspension. It not only saves space but also makes shock absorption more effective for your vehicle.

Active Suspension:

It uses electronic controls and sensors to adjust the Suspension in real time based on your driving conditions, improving comfort and performance.

Hydropneumatic Suspension:

It Combines fluid and gas elements to provide a soft and smooth ride.

Leaf Spring Suspension:

It is commonly found in the rear Suspension of trucks and heavy-duty vehicles, consisting of several layers of metal strips.

Electronic Controlled Suspension:

This type of suspension allows for electronic adjustments in the stiffness of the Suspension, providing a balance between comfort and sporty handling.

Which type of suspension is best depends on factors such as why you are using your vehicle, for example, whether to drive for long hours for business or just for family use, the design of your car and your priority while driving.

More than often, manufacturers select the suspension that goes best with the vehicle. Still, you can get it customized based on your preferences and driving intent.

The Role of 5 axis CNC Machining in Advanced Vehicle Suspensions

At the heart of these sophisticated suspensions that we have discussed above so far lies the precision and versatility of 5 axis CNC machining. This advanced manufacturing technique has revolutionized how suspension components are produced, empowering engineers to create parts with precision and complexity.

How 5 axis CNC Machining Works

Imagine a sculptor working with a block of marble. In the world of 5 axis CNC machining, the sculptor is a computer, and the marble is a solid metal block. Using five simultaneous axes of movement, the computer guides a cutting tool with incredible precision, carving out intricate shapes and geometries that would be impossible to achieve by hand.

Benefits of 5 axis CNC Machining for Vehicle Suspensions

The benefits of 5 axis CNC machining for vehicle suspensions are numerous. Here are some of the benefits:

Enhanced Performance: With 5 axis CNC machining, engineers can create suspension components with precise geometries and tight tolerances, resulting in superior handling, stability, and ride comfort.
Lightweight Construction: 5 axis CNC machining helps the production of light, high-strength components, contributing to overall weight reduction of your car and improved fuel efficiency.
Customizable and Precise: 5 axis CNC machining allows for producing suspension components customized to your car’s specific requirements and performance specifications.
Faster Manufacturing: The efficiency of 5 axis CNC machining simplify the production process, reducing lead times and increasing manufacturing output.
Versatility: 5 axis CNC machining can handle various materials, from lightweight aluminum alloys to high-strength steels, offering greater design flexibility.

Applications of 5 axis CNC Machining in Suspension Components

5 axis CNC machining plays a crucial role in the production of various critical suspension components:

Suspension Arms: These load-bearing components are meticulously shaped using 5 axis CNC machining to ensure optimal strength, stiffness, and weight distribution.
Control Arms: 5 axis CNC machining allows for creating complex control arms with precise geometries, ensuring accurate wheel alignment and handling control.
Knuckle Assemblies: The intricate shapes of knuckle assemblies, which connect the suspension arms to the wheels, are expertly machined using 5 axis CNC technology.
Steering Knuckles: 5 axis CNC machining enables the production of steering knuckles with precise bearing interfaces and integrated steering linkage points.
Spring Seats: The precise contours of spring seats, which support and position the suspension springs, are accurately machined using 5 axis CNC techniques.

The Future of 5 axis CNC Machining in Vehicle Suspensions

As automotive technology continues to evolve, the role of 5 axis CNC machining in designing advanced vehicle suspensions will expand further. With its ability to create complex, lightweight, and high-precision parts, will undoubtedly remain an integral part of the suspension design process, ensuring that vehicles continue to provide unparalleled driving experiences.

Important Suspension System Tips for Vehicle Owners

The suspension system is an important part of your vehicle, and it’s important to take care of it. Here are some tips for maintaining performance, safety, and comfort:

Regular Inspections

Regularly inspect your vehicle’s suspension components for signs of wear, damage, or leaks. The Early detection can prevent further damage and ensure a smoother ride.

Check for Unusual Noises

Pay attention to any clunking or knocking sounds when driving over bumps. More than often unusual noises may mean issues with suspension components, and addressing them timely can prevent more serious problems.

Maintain Proper Tire Inflation

Keep tires properly inflated according to the manufacturer’s recommendations. Correct tire pressure provides even weight distribution, reducing stress on suspension components and improving fuel efficiency.

Alignment Checks

Get regular wheel alignments, especially after hitting potholes or curb impacts. Proper alignment extends tire life, improves handling, and prevents uneven wear on suspension parts.

Vehicle Suspension System

Figure: showcasing the importance of alignment of suspension system components

Smooth Driving Habits

Avoid aggressive driving, excessive speeding, and harsh braking.

Gentle driving reduces stress on the suspension, promoting consistent performance.

Load Capacity Awareness

Adhere to the manufacturer’s load capacity recommendations. Overloading a vehicle can weaken the suspension, leading to early wear and decreased performance.

Professional Inspections

Schedule periodic inspections by a qualified mechanic. Professional inspections can identify issues early, ensuring timely repairs and preventing safety hazards.

Upgrade Considerations

Explore suspension upgrades for improved performance. Upgrades can improve handling, responsiveness, and overall driving experience, suitable for those seeking a customized ride.

Additional Tips:

Use the correct type of suspension fluid. The type of suspension fluid you use will depend on the type of suspension system you have. Be sure to check your owner’s manual for the recommended fluid type.
Replace your suspension shocks and struts regularly. Shocks and struts wear out over time and can affect the handling of your vehicle. Be sure to replace them according to the manufacturer’s recommended schedule.
Avoid driving over potholes and other bumps. Potholes and bumps can damage your suspension system. If you can’t avoid them, try to slow down and go over them smoothly.

In conclusion, the suspension system is a crucial part of any vehicle, playing an important role in providing a smooth, comfortable, and safe ride. By absorbing bumps and irregularities in the road surface, the suspension system helps to maintain tire contact with the road, improving stability.

It also reduces noise, vibration, and harshness, making the driving experience more enjoyable. Over all the suspension system is as crucial to the driving experience as the vehicle itself. Advanced manufacturing techniques like 5 axis CNC machining have also transformed how suspension components are produced.

In essence, the suspension system is the silent guardian of a smooth and enjoyable ride, ensuring that every journey is a testament to the harmonious interplay of technology and engineering.

Automotive

Russell’s early departure leaves Lando Norris on pole at the Hungarian F1 GP.

(CTN News) – Lando Norris and his McLaren squad survived a tough qualifying session for the Hungarian Grand Prix, but they know they must perform on Sunday.

Lando Norris needed to win Budapest after Oscar Piastri locked off the top row in the field’s fastest McLaren. Recent races have been costly owing to wasted opportunities and little mistakes.

He matched Max Verstappen’s pole lap at the Hungaroring, who was unhappy to finish third. In a confident and aggressive approach, the 24-year-old finished more than three tenths ahead of the Dutchman, hitting the apexes.

Piastri followed Lando Norris by two hundredths of a second on the second hot run, demonstrating McLaren’s speed.

McLaren is doing well since Lando Norris won the Miami Grand Prix.

His potential triumphs have been cost by team and driver error, for which both parties have taken responsibility. On Sunday, he and McLaren will know they must do well.

Norris was quietly pleased with his historic first pole in Hungary and third overall. Although confident, McLaren will also be proud of their recent race progress. No one has won the pole in Budapest since Lewis Hamilton won the race and flag in 2012.

Norris and his crew recognize they must capitalize on closing gaps with 12 races left to drive Verstappen to the finish. Lando Norris understands. Behind Verstappen by 84 championship points.

“I know we missed out on some races, but we did the best we could in every one of them, and I don’t want to get back into all that stuff,” he said. I expect Oscar and Max to challenge me in the rear, not a clean weekend.

“Every location and point must be maximized; the more we can do to return to Max and Red Bull, the better.”

Hungary is a great opportunity since Lando Norris Verstappen was plainly unhappy with his car and outperformed. This disappointed him twice because the team had swiftly upgraded this race.

Verstappen had stated that the upgrades will define the second half of the season, but he admitted that he did not think they had gone far enough and could not defeat the McLarens.

“The changes are effective, but we still need more as we are not at the top,” said he. “Despite the imbalance, I liked the laps. I was pushing hard, so you had these little moments. Fast lap times are less crucial today. Simple: we need to work more because we’re moving slower. McLaren’s qualifying performance suggests a lot of ground to cover.

Lando Norris completed his best lap despite two crash-related stoppages.

Verstappen looked great in dry Q3 hot laps. He set a record with a lap time of 1 minute, 15.555 seconds and was quickest through each sector.

Lando Norris followed and pushed through the corners with fearlessness, posting a perfect 1:15.227 lap time. Piastri improved to second place on the penultimate laps while Verstappen did not, and Yuki Tsunoda’s crash halted the session.

A tardy coda didn’t matter when practice resumed because the last two minutes on old tires were worthless. McLaren has all the cards, but they must perform at the highest level to prove the legendary brand can win again.

Carlos Sainz of Ferrari was fourth and Lewis Hamilton of Mercedes fifth. George Russell, Sainz’s teammate, was unexpectedly ousted in the first round.

Sergio Pérez of Red Bull struggled again in the first qualifying round. He hit the curb, lost the rear at turn eight, and crashed, interrupting the session.

Poor performance again for the Mexican, whose Red Bull berth is in risk after a succession of poor performances, especially in qualification. His contract, recently extended to 2025, may have a performance clause, and Red Bull is unlikely to tolerate him underperforming for long. He was sixteen.

Russell fell behind because Lando Norris Mercedes didn’t fuel the car until the session ended. The British driver was eliminated in 17th place after staying out when the track dried after the break.

Charles Leclerc of Ferrari placed sixth, Fernando Alonso and Lance Stroll of Aston Martin placed seventh and eighth, Daniel Ricciardo of RB placed nine, and Tsunoda placed tenth.

Nico Hülkenberg and Kevin Magnussen of Haas finished 11 and 15, Valtteri Bottas of Sauber 12 and Alex Albon and Logan Sargeant of Williams 13 and 14. Esteban Ocon and Pierre Gasly placed ninth and twentieth for Alpine, while Guanyu Zhou placed eighth for Sauber.

SOURCE: GN

Automotive

M5 Partially Closed as Cullompton-Exeter Crash Hospitalizes Two

(CTN News) – Two people were sent to the hospital for treatment as a result of the M5 tragic vehicle accident that happened in Devon.

The accident between two vehicles was the cause of the disaster. One more consequence of the crash is that it has left the M5 partially blocked to traffic to this day.

Between junction 28 for Cullompton and junction 29 for Exeter, the highway was blocked in both directions; however, one lane on the southbound carriageway has been opened up for previously closed traffic.

In a statement issued by the South Western Ambulance Service NHS Foundation Trust, they stated that they were notified of a traffic accident that had happened in the Exeter district at 2:29 p.m. on Friday, July 12.

M5 happened in Exeter, according to reports.

Furthermore, information was given to them by the South Western Ambulance Service.

To provide medical assistance to those injured, four land ambulances, each with two crews, an air ambulance, a critical care M5 vehicle, a doctor, an operations officer, and a responding officer were dispatched to the scene of the incident.

Furthermore, a critical care vehicle was dispatched. We also dispatched an air ambulance to the scene of the event.

Two patients were transported to their respective hospitals: one was transported by land ambulance to the Royal Devon and Exeter Hospital, while the second patient was flown there by air ambulance.

After being moved, the two patients were sent to hospitals in Devon and Exeter, respectively. Simultaneously, both patients were transferred to their respective sites at the same time.

Here’s what Devon and Somerset M5 Fire and Rescue Service said:

“We responded to the scene of a road traffic collision on the M5 at 2.30 p.m. today, between junctions 28 and 29.” The statement cited above was part of an official declaration.

A car that had been hit by another car coming from the other direction had two persons inside that had been rescued. It had been traveling in the other direction.

We offered support as the people were being taken out of the car. These people are now receiving medical assistance from the ambulance service in order to fulfill their duties.

The event caused significant delays for the M5 and the routes that pass through Exeter during the period when traffic was being redirected. In order to accommodate the traffic, this was being done.

A southbound vehicle experienced wheel failure, causing it to cross the center reserve and merge with the northbound road approaching. The car was going the wrong way, which is why this happened. The vehicle was traveling southward at that precise moment.

National Highways indicated that based on the facts they have provided, it is expected that the police would begin their investigation into the occurrence given the magnitude of the calamity that occurred. The entity that made this information public was National Highways.

The Devon and Cornwall Police Department issued the following statement:

“We know the M5 closure is causing traffic.”

The statement that was released is located beneath you. “We will get people moving safely when we can but please bear with us while we deal with the incident and causalities at the scene.”

In order to accommodate cars and other small vehicles that were traveling on the now-closed northern route towards M5 Taunton and Bristol, the back of the line has been shifted.

This was done to create space for these cars, which were heading towards Taunton and Bristol. The purpose of this activity was to provide space for larger cars. At this point, it seems like more and more vehicles are being stopped from going forward.

Due to this incident, a second lane has been opened up for use by any and all vehicles traveling southward.

SOURCE: ITV

Automotive

Honda to Cease Production at One of its Thailand Auto Factories

(CTN News) – The Japanese vehicle firm Honda Motor made the news in a statement that was posted on Tuesday. The statement stated that the company intends to center its production at the site that it operates in the province of Prachinburi.

As a consequence of this, the production of automobiles will be halted at the facility that it operates in the province of Ayutthaya in Thailand by the year 2025.

The more difficult circumstances that the second-largest car manufacturer in Japan is facing in the country of Thailand, which is located in Eastern Southeast Asia, are exemplified by this move. Thailand is located in Southeast Asia.

There are several reasons for this, including the fact that Chinese firms are determined to grow their market share in Thailand, and a growing number of consumers are expressing an interest in electric vehicles (EVs). They both play a role in contributing to the problem.

The combined output of automobiles produced by Honda’s two facilities has fallen throughout the course of the succeeding four years, going from 228,000 vehicles in 2019 to less than 150,000 vehicles annually. This downward trend has occurred during the course of the past four years.

The preceding four years have been the time period during which this decline has taken place. With regard to the sales that the company has made in Thailand throughout the course of the past four years, there has been a consistent range of less than 100,000 to less than 100,000 for the entirety of this time period.

This is according to Honda’s spokeswoman.

When the factory first opened its doors in 1996, the company anticipates that it would continue to manufacture vehicle components at that location. When the firm finishes manufacturing vehicles at the Ayutthaya facility in the next year, the spokesperson stated that the company intends to continue producing automobile components at the plant.

In accordance with the statement that was given by the spokesman, the Prachinburi factory, which was built in 2016, will be utilized for the purpose of integrating the facilities with which automobiles are created. This was said in the statement. There are only two factories in Thailand that are owned and operated by the vehicle manufacturer, and these two factories are the only ones in the country.

According to the statement made by a spokeswoman for Honda in Thailand, the company’s goal is to reduce the disparity between the number of automobiles it produces and the number of sales it has experienced in the nation.

According to the remark that was made by the spokesman for the company, the automobile manufacturer are already exporting their products from Thailand, particularly to other Southeast Asian countries such as Indonesia and the Philippines. According to a statement that was sent by a spokeswoman for the company.

Currently, Honda has no plans to invest in Thailand.

When it comes to mainland China, Honda and Nissan Motor, a Japanese automobile manufacturer that competes with Honda, have been hit particularly hard by competition from rising Chinese manufacturers.

Nissan Motor is a competitor of Honda. As a result of the fact that these businesses provide reasonably priced plug-in hybrids and electric vehicles that are loaded with software, a significant number of customers have been drawn to them.

Now, Japanese automobile manufacturers are at risk of losing clients in countries outside of China, such as those in Southeast Asia, to Chinese companies that are increasingly attempting to increase the quantity of automobiles they export and build up operations outside of China.

As a result, Honda Japanese automobile manufacturers are facing a potential loss of customers. They are exposed to this danger as a result of the fact that Japanese brands compete with Chinese brands in these locations.

BYD, a Chinese manufacturer of electric vehicles, recently launched a plant in Thailand that will be responsible for the production of automobiles that are powered by electronic batteries.

This plant was established last week. The Chinese electric car manufacturers are beginning to establish facilities in the country, and this factory is a component of the wave of investments that they are making in the country. These investments have a total value that is greater than 1.44 billion dollars together.

SOURCE |SCMP