The AutomotiveSuspension SystemsReport

SupplierBusiness

2013 Edition

The Automotive Suspension Systems Report

© 2013 IHS Global Limited 3

CONTENTS

Introduction ................................................................................................................ 7 Key market drivers .................................................................................................... 12

Fuel efficiency and CO2 emissions .......................................................................... 12 The United States ................................................................................................ 12 The European Union ........................................................................................... 13 Japan .................................................................................................................. 14 China .................................................................................................................. 14 Other countries .................................................................................................... 15

Materials considerations ......................................................................................... 15 Increasing electrification ......................................................................................... 20

Systems integration.............................................................................................. 20 Challenges and barriers ........................................................................................... 24 Chassis and suspension weight reduction ................................................................ 27 Suspension performance ......................................................................................... 28

Design compromise ............................................................................................. 28 Moving from passive to active suspension ............................................................... 30 Kinematics and elastokinematics ............................................................................ 34

The ‘Skyhook control strategy .............................................................................. 35 Suspension element technology ............................................................................... 36

Control arms ....................................................................................................... 37 Front suspension ................................................................................................. 38 Rear suspension................................................................................................... 39 Spring systems ..................................................................................................... 40 Pneumatic and hydropneumatic spring systems .................................................... 41 Electronic spring systems ..................................................................................... 46 Composite springs ............................................................................................... 48

Dampers/shock absorbers....................................................................................... 49 Shock absorber design.......................................................................................... 49 Acceleration Sensitive Damping .......................................................................... 50 Gas charged shock absorbers................................................................................ 50 Position Sensitive Damping ................................................................................. 51 Dynamic Ride Control ........................................................................................ 51 BWI’s manual selectable ride ............................................................................... 52 BWI’s Bi-State real time damping system ............................................................. 52 Adaptive damping system .................................................................................... 53 Frequency Dependent Damping (FDD) ............................................................... 54 ZF preloaded valve and vario damper technology ................................................. 56 ZF Sachs Continuous Damping Control............................................................... 57 BWI MagneRide: Magneto-rheological damping .................................................. 59

The Automotive Suspension Systems Report

© 2013 IHS Global Limited 4

Stabilisers or anti-roll bars .................................................................................... 61 Knuckles/Uprights .............................................................................................. 64 Ball joints ............................................................................................................ 64 Bushings ............................................................................................................. 65

Supplier Profiles ........................................................................................................ 66 Benteler .................................................................................................................. 66 BWI Group ............................................................................................................ 69 KYB ...................................................................................................................... 71 Magneti Marelli ..................................................................................................... 74 Mando Corporation................................................................................................ 79 Metaldyne .............................................................................................................. 83 NHK Spring ........................................................................................................... 85 Sanluis ................................................................................................................... 88 ThyssenKrupp ........................................................................................................ 90 Tower International ................................................................................................ 95 TRW Automotive .................................................................................................. 97 WABCO ............................................................................................................... 106 ZF......................................................................................................................... 113

FIGURES Figure 1: Conventional suspension compromises [Source: Daimler] .............................. 8 Figure 2: Average power consumption 1990 – 2010 for mid size and luxury cars [Source: AABC Europe] ............................................................................................................ 9 Figure 3: Electrical power requirements for NEDC and actual customer requirements for various vehicle classes [Source: BMW]....................................................................... 10 Figure 4: The extended performance envelope for fully active suspension compared to conventional passive and semi-active systems [Source: TU München] ......................... 11 Figure 5: Fuel economy standards to 2015 for selected countries (US mpg) [Source: Various] .................................................................................................................... 14 Figure 6: The impact of weight on fuel consumption [Source: ZF Sachs] ..................... 16 Figure 7: Cost comparison of lightweight vehicle structures [Source: Massachusetts Institute of Technology] ............................................................................................. 16 Figure 8: Additional costs entailed by tougher European CO2 legislation for a vehicle with emissions of 161g per km [Source: TRW] ........................................................... 17 Figure 9: Average profit per vehicle versus CO2 compliance costs [Source: A T Kearney] ................................................................................................................................. 18 Figure 10: The relationship between functions and control units to 2014 [Source: ADL] ................................................................................................................................. 20 Figure 11: The growth of integrated functions [Source: BMW] ................................... 21 Figure 12: X-by-wire roadmap [Source: Ricardo] ........................................................ 21 Figure 13: An active stabiliser bar system [Source: BWI Group] ................................. 22 Figure 14: BMW’s Dynamic Drive system [Source: BMW] ........................................ 23

The Automotive Suspension Systems Report

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Figure 15: Ford Focus control blade rear suspension [Source: Ford] ............................ 23 Figure 16: AAM’s I-Ride suspension module [Source: AAM] ..................................... 26 Figure 17: Contribution to weight reduction [Source: Centro Ricerche Fiat] ................ 28 Figure 18: Conventional suspension compromises for passive and active suspension systems [Source: Daimler] ......................................................................................... 29 Figure 19: The complex functional harmony required to provide driving quality [Source: Ford] ......................................................................................................................... 30 Figure 20: A schematic of active and semi-active suspension [Source: RMIT] ............. 31 Figure 21: A schematic showing the Mercedes-Benz Pre-Scan technology [Source: Daimler] ................................................................................................................... 33 Figure 22: Mercedes Benz’s Pre-Scan technology [Source: Daimler] ........................... 34 Figure 23: Axle and multi-axle computer simulation [Source: IAV Automotive Engineering] .............................................................................................................. 35 Figure 24: A schematic representation of the skyhook control strategy [Source: ZF Sachs] ....................................................................................................................... 36 Figure 25: Suspension control arm configurations [Source: ZF Friedrichshafen] .......... 37 Figure 26: Typical control arm designs [Source: ZF Friedrichshafen] .......................... 38 Figure 28: Continental's 4-Corner air suspension system [Source: Continental] ........... 41 Figure 29: CO2 reduction through the use of pneumatic suspension systems ................ 44 Figure 28: Continental's air suspension system [Source: Continental AG] ................... 44 Figure 30: Bose's fully electromechanical front suspension model [Source: Bose] ......... 47 Figure 31: Sogefi’s composite springs [Source: Sogefi] ................................................ 48 Figure 32: Acceleration sensitive damping [Source: Tenneco] ..................................... 50 Figure 33: Audi RS5 chassis featuring dynamic ride control [Source: Audi]................. 52 Figure 34: suspension motion sensors [Source: BWI] .................................................. 53 Figure 35: A schematic of Tenneco’s Continuously Controlled Electronic Suspension [Source: Tenneco] ..................................................................................................... 55 Figure 36: A schematic of Tenneco’s integrated Kinetic H2 CES system [Source: Tenneco] ................................................................................................................... 56 Figure 37: Comparison between standard and pre-loaded valve performance [Source: ZF Sachs] ....................................................................................................................... 57 Figure 38: Graph showing the range in which CDC can continuously vary damping forces in compression and rebound [Source: ZF Sachs] ............................................... 58 Figure 40: CDC dampers with internal and external valves [Source: ZF Sachs] ........... 58 Figure 42: Cross section of a MagneRide actuator [Source: BWI] ............................... 59 Figure 43: Comparison of force-velocity characteristics of a MagneRide damper, typical variable valve dampers and a passive damper [Source: BWI] ...................................... 60 Figure 44: ZF Sach’s Active Roll Stabilisation system [Source: ZF Sachs] ................... 62

TABLES

Table 1: Weight reduction in lightweight shock absorber assemblies [Source: ZF Friedrichafen] 27

The Automotive Suspension Systems Report

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Table 2: Front axle design proportions, worldwide light passenger vehicles (%) [Source: ZF Friedrichshafen] ................................................................................................... 38 Table 3: Front axle design by segment, worldwide light passenger vehicles (%) [Source: ZF Friedrichshafen] ................................................................................................... 39 Table 4: Rear axle design proportions, worldwide light passenger vehicles (%) [Source ZF Friedrichshafen] ................................................................................................... 39 Table 5: Rear axle design by segment, worldwide light passenger vehicles (%) [Source: ZF Friedrichshafen] ................................................................................................... 40