ihs automotive - sae international the advanced chassis systems report 2013 edition...

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The Advanced Chassis Systems Report

2013 edition supplierbusiness.com

Sectoral Report

IHS Automotive

2013 edition 2 © 2013 IHS

IHS Automotive SupplierBusiness | The Advanced Chassis Systems Report

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ContentsIntroduction ..................................................................................................................................................................... 6

Electrification within the chassis .............................................................................................................................. 7Chassis performance .................................................................................................................................................. 9

Design compromise ..................................................................................................................................................... 9Manufacturing economics ........................................................................................................................................ 10Platform development and component commonality ........................................................................................... 11Noise vibration harshness ........................................................................................................................................ 13

Key Development drivers ............................................................................................................................................. 14Greenhouse gas emissions and fuel efficiency ..................................................................................................... 14

The European Union .................................................................................................................................................. 14The United States ....................................................................................................................................................... 15Japan ......................................................................................................................................................................... 16China ......................................................................................................................................................................... 16Other countries ...........................................................................................................................................................17

Chassis materials developments ............................................................................................................................. 17Increasing electrification .......................................................................................................................................... 21

Electronic systems integration .................................................................................................................................... 21The packaging dilemma ............................................................................................................................................ 25The future for chassis design ................................................................................................................................... 26

Suspension systems..................................................................................................................................................... 28Challenges and barriers ............................................................................................................................................ 31

Suspension technology development ........................................................................................................................ 34passive moving to active .......................................................................................................................................... 34Kinematics and elastokinematics ........................................................................................................................... 35Suspension element technology ............................................................................................................................. 36

Control arms .............................................................................................................................................................. 36Spring systems .......................................................................................................................................................... 39

Active body control.................................................................................................................................................... 39Anti-roll or stabiliser systems ...................................................................................................................................... 40

Adaptive damping system ........................................................................................................................................ 42Air suspension ........................................................................................................................................................... 43

Pneumatic and hydropneumatic systems ................................................................................................................... 43The ‘skyhook control strategy .................................................................................................................................... 47

Active suspension systems ...................................................................................................................................... 47Electronic Damper Control (EDC) ............................................................................................................................... 47Active Suspension Geometry (ASG) ........................................................................................................................... 48

Semi-active suspension ............................................................................................................................................ 49BWI MagneRide: Magneto-rheological damping ........................................................................................................ 49

Active electronic suspension system ..................................................................................................................... 51Recuperative damping systems ................................................................................................................................. 52

Future trends .............................................................................................................................................................. 53Chassis and corner modules ....................................................................................................................................... 55Steering systems .......................................................................................................................................................... 58



Electrically Power Assisted Steering (EPAS) ......................................................................................................... 58Surface acoustic wave ............................................................................................................................................... 60Software enabled features ......................................................................................................................................... 61

Electro-Hydraulic Power Steering (EHPS) .............................................................................................................. 61Electric Power Steering (EPS) .................................................................................................................................. 62

Active Front Steering (AFS) ......................................................................................................................................... 62Four-wheel steering .................................................................................................................................................. 64Steer-by-wire .............................................................................................................................................................. 65Automated parking ................................................................................................................................................... 67

Braking system development ...................................................................................................................................... 69Anti-Lock Braking System (ABS) ................................................................................................................................ 69Electronic Braking System (EBS) or Electronic Brake Distribution (EBD) ..................................................................... 70Brake Assist (BA) ........................................................................................................................................................ 70Autonomous emergency braking ............................................................................................................................... 70Ceramic composite brakes ........................................................................................................................................ 70Lightweight brake discs.............................................................................................................................................. 71

Brake-by-wire ............................................................................................................................................................. 71Electro-hydraulic brake-by-wire .................................................................................................................................. 71Electro-mechanical brake-by-wire .............................................................................................................................. 72

Regenerative braking systems and brake blending .............................................................................................. 74Vehicle stability systems .......................................................................................................................................... 78

Four-wheel drive (4WD) ................................................................................................................................................ 79Emissions and Fuel Economy ..................................................................................................................................... 79

Active Torque Dynamics (ATD) ................................................................................................................................. 79Safety and AWD ......................................................................................................................................................... 80Technologies and Challenges ..................................................................................................................................... 81

Electric AWD ............................................................................................................................................................... 82Integration of Control Systems ................................................................................................................................... 82

Active All Wheel Drive (AWD) .................................................................................................................................... 82Torque vectoring ........................................................................................................................................................ 83Future trends .............................................................................................................................................................. 83

Supplier Profiles ............................................................................................................................................................ 84Autoliv ......................................................................................................................................................................... 84Benteler ....................................................................................................................................................................... 91Bharat Forge ............................................................................................................................................................... 94Bosch .......................................................................................................................................................................... 97Brabant Alucast ........................................................................................................................................................110BWI Group ..................................................................................................................................................................111Casti SpA ...................................................................................................................................................................113Continental ................................................................................................................................................................114ixetic .......................................................................................................................................................................... 130JTEKT ........................................................................................................................................................................ 132KYB ............................................................................................................................................................................ 135Magna ........................................................................................................................................................................ 138Magneti Marelli ........................................................................................................................................................ 147Mando Corporation ................................................................................................................................................. 152Mubea ........................................................................................................................................................................ 157NSK ........................................................................................................................................................................... 159Schaeffler ................................................................................................................................................................. 163Sogefi ........................................................................................................................................................................ 168tedrive ....................................................................................................................................................................... 171Tenneco ..................................................................................................................................................................... 173ThyssenKrupp .......................................................................................................................................................... 179Tower International .................................................................................................................................................. 186



FiguresFigure 1: Additional functionality requires higher voltages – 48 volts ..................................................................... 8Figure 2: Conventional suspension compromises ..................................................................................................... 9Figure 3: Matching and similar parts for the Volkswagen B/C platform ................................................................ 10Figure 4: Common and matching parts (Chassis, drivetrain, steering system) for the Volkswagen B/C platform .......................................................................................................................................................................... 11Figure 5: Progress from platform through modular to assembly kit strategy for Volkswagen Golf .................. 11Figure 6: Volkswagen MQB platform .......................................................................................................................... 12Figure 7: Additional functionality requires higher voltages – 48 volts ................................................................... 12Figure 8: The complex functional harmony required to provide driving quality ................................................... 13Figure 9: Global CO2(g/km) progress normalised to NEDC test cycle ................................................................... 14Figure 10: CO2 (g/km) performance and standards in the EU new cars 1994 - 2011 ............................................ 15Figure 11: Additional functionality requires higher voltages – 48 volts.................................................................. 15Figure 12: Weight share of modules and their weight increase .............................................................................. 17Figure 13: Aluminium steering knuckle ...................................................................................................................... 18Figure 14: A lightweight strut with a fibreglass wheel carrier................................................................................. 19Figure 15: Average profit per vehicle versus CO2 compliance costs ..................................................................... 20Figure 16: Global market revenue forecast for OEM electronic systems (billions) .............................................. 21Figure 17: Electronic Stability Control installation rates ......................................................................................... 22Figure 18: High performance domain control ECUs can simplify overall network complexity .......................... 23Figure 19: A schematic of data fusion from multiple sensors ................................................................................. 24Figure 20: X-by-wire roadmap ..................................................................................................................................... 25Figure 21: Average power consumption 1990 – 2010 for mid size and luxury cars .............................................. 29Figure 22: Electrical power requirements for NEDC and actual customer requirements for various vehicle classes ........................................................................................................................................................................... 30Figure 23: The extended performance envelope for fully active suspension compared to conventional passive and semi-active systems ............................................................................................................................... 31Figure 24: Ford Focus control blade suspension...................................................................................................... 32Figure 25: Additional functionality requires higher voltages – 48 volts ................................................................. 34Figure 26: Typical control arm designs ...................................................................................................................... 37Figure 27: Suspension control arm configurations ................................................................................................. 37Figure 28: BWI’s Active Stabiliser Bar System .......................................................................................................... 40Figure 29: Dynamic Ride Control main module schematic ..................................................................................... 42Figure 30: A schematic of Monroe’s kinetic system................................................................................................. 42Figure 31: Continental’s 4-Corner air suspension system....................................................................................... 43Figure 32: Continental’s air suspension system ....................................................................................................... 45Figure 33: CO2 reduction using pneumatic suspension systems ........................................................................... 46Figure 34: Graph showing the range in which CDC can continuously vary damping forces in compression and rebound .................................................................................................................................................................. 48Figure 35: CDC dampers with internal and external valves .................................................................................... 49Figure 36: Cross section of a MagneRide actuator .................................................................................................. 50Figure 37: Comparison of force-velocity characteristics of a MagneRide damper, typical variable valve dampers and a passive damper .................................................................................................................................. 51Figure 38: Bose’s fully electromechanical front and rear suspension modules ................................................... 52Figure 39: A schematic representation of Genshock technology .......................................................................... 53Figure 40: Steering system design compromise (EPAS) .......................................................................................... 54

Trelleborg .................................................................................................................................................................. 190TRW Automotive ...................................................................................................................................................... 194VB-Airsuspension .................................................................................................................................................... 203WABCO ...................................................................................................................................................................... 204ZF ...............................................................................................................................................................................209



TablesTable 1: Comparison between various automotive suspension systems .............................................................. 36Table 2: Front axle design proportions, worldwide light passenger vehicles (%) ................................................ 38Table 3: Front axle design by segment, worldwide light passenger vehicles (%) ................................................. 38Table 4: Rear axle design proportions, worldwide light passenger vehicles (%) ................................................. 38Table 5: Rear axle design by segment, worldwide light passenger vehicles (%) .................................................. 39Table 6: Advantages of EPAS ....................................................................................................................................... 59

Figure 41: BWI’s corner module .................................................................................................................................. 55Figure 42: MOBIS’ front chassis module ................................................................................................................... 56Figure 43: Additional functionality requires higher voltages – 48 volts ................................................................. 56Figure 44: Mechanical and electric control systems for EPAS ............................................................................... 59Figure 45: Differing steering rack types, force and mechanical performance by vehicle class ........................ 60Figure 46: A schematic of AFS used in a driver assistance function to enhance vehicle stability .................... 64Figure 47: Renault’s active four-wheel steer systems as fitted to the Laguna GT ............................................... 65Figure 48: Nissan’s steer-by-wire system .................................................................................................................. 66Figure 49: A schematic illustrating 4 Wheel Active Steer functionality ................................................................. 66Figure 50: Ford’s park assist system .......................................................................................................................... 67Figure 51: Brake control systems roadmap ............................................................................................................... 69Figure 52: Continental’s electronic wedge brake on test ........................................................................................ 72Figure 53: Continental’s electro-hydraulic combi braking system layout ............................................................. 73Figure 54: By-wire brake system layout with regeneration ..................................................................................... 74Figure 55: Mazda’s supercapacitor based regenerative braking system layout .................................................. 75Figure 56: Continental’s regenerative braking system layout ................................................................................. 76Figure 57: Comfortable regeneration requires uncoupling the pedal and quiet and highly dynamic of braking force regulation ............................................................................................................................................................. 77Figure 58: Bosch’s yaw torque compensation system. ........................................................................................... 78Figure 59: Attributes of lifestyle and AWD wagons and performance AWD vehicles .......................................... 80Figure 60: Attributes of SUVs and crossover vehicles ............................................................................................. 81

ihs automotive - sae international the advanced chassis systems report 2013 edition...

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