ACTL_2

Composite Transversal Leaf Spring for Automotive sector.

 

 

Description

The aims of the project are design, construction and validation, in a relevant environment, of the Composite Transversal Leaf Spring prototype, designed to replace the suspension system already on current vehicles, but also based on innovative electric machines, where, due to the low battery autonomy, the problem of weight reduction is even more felt. This project represents the concrete response to the needs of the increasingly competitive Automotive sector, which requires:
• to lower weights with a minimum cost increase (in some cases at the same cost)
• to reduce the Time to Market by being able to have a design methodology and allowing car manufacturers to be able to manage the integration of composite components in production vehicles as well as for small productions, luxury productions, motorsport and special fittings, where these types of materials are currently used.

Result to be enhanced

The suspension system consists of a Transversal Leaf Spring whose main innovation lies in the great integration of functions (in addition to the advanced use of composite materials). This integration allows to achieve weight and cost savings targets and volume packaging optimization, not feasible with traditional suspension designs. In this specific case, the project Transversal Leaf Spring would join the function of Spring, Suspension Arm and Anti-roll Bar. Therefore, the “functions Integration” allows you to reduce the number of very expensive components (in this case Spring, Suspension Arm, Anti-roll Bar and related Bushings). With the project Transversal Leaf Spring solution, the Spring would be integrated into the Leaf Spring and this would allow the shock absorber attachment point to be significantly lowered, letting incredible freedom to the Car Designers, improving all passive safety performance in the event of a frontal impact.

Why is it important?

The innovative layout has a significant impact on the entire vehicle system, which allows you to have the best synergy with new automotive technologies, such as hybrid and electric cars. The level of integration leads to the reduction of the complexity of the suspension system maintaining the same reliability and performance. This results in a significant weight reduction, with a consequent emissions reduction (positive environmental impact).