Client

US based leading
EV manufacturer

Industry

Automobile

Challenge

The client is a new US-based electric vehicle (EV) manufacturer aiming to capitalize on the growing demand for sustainable transportation solutions. The challenge was to capture an early foothold in the market. The design process can be expedited by substituting electric motors and batteries for an internal combustion engine but it introduces complexities related to vehicle dynamics. The weight and center-of-gravity position of the vehicle is altered, which impacts the dynamic characteristics of the vehicle. Modifications to the suspension system are necessary to maintain similar performance and safety standards as those of fossil fuel-based vehicles.

Service Area

Advance Simulation Engineering

Timeline

September 2023 to February 2024

A simplified tire model was used to establish interaction of the suspension system with various measured road profiles.

Key Engineering Solutions

1. The individual suspension system was assembled to create a comprehensive vehicle model.

2. Transmitted forces and torques experienced when vehicles navigate across diverse road profiles was analysed.

Solutions

TimeTooth initiated the project by mapping hard points of the suspension system. Topologically equivalent modeling was done, emulating front and rear suspension systems. Modified MacPherson strut was used as front and De Dion suspension for rear. Essential components like coil springs, dampers, jounce/rebound bumpers, joints, and bushes with appropriate stiffness and damping parameters were carefully modeled. MBD was employed to extract forces and torques applicable at various locations for subsequent detailed component-level study. Then the individual suspension system was assembled to create a comprehensive vehicle model. A simplified tire model was used to establish interaction of the suspension system with various measured road profiles. Stabilizer bar was modified to match roll stiffness. Further transmitted forces and torques experienced when vehicles navigate across diverse road profiles was analyzed. Analysis was shared with the client facilitating their team in making informed design decisions based on FEA studies.

Key Highlights

ROI for the client

EV’s time to market was reduced considerably.