Project Methodology of Designing a suspension system for light weight

electric vehicles
Identification of the problem
Unlike IC engines electric motors can provide a high torque at an instant and provide huge
accelerations due the unique characters of electric motors. With these features drives tend
to drive faster. But most of the times the suspension characters are not designed for such
speeds and accelerations. There for the drivers tend to stiffen their vehicle’s suspension in
cost of the comfort. Systems with different suspensions modes are either very expensive or
the cheap system do not provide enough performance. Therefore the need of a suspension
system with two modes for electric vehicles that is both cheap and well performing is
eminent.
Problem definition
Designing an inexpensive suspension system with configurations for high speed
manoeuvrability and comfort in general usage.
Literature Review
Objectives of literature review are as follows

• Identify the suspension systems currently in use that address our design problem
• Identify the methods yet to be used but in research stage at the moment.
• Identifying the research gaps where adequate studies have not been done.
• Identifying the performance criteria required to be attained at both modes and the
methods of data acquisition used.
• Identifying the methods of performance evaluations and validation of the results.
Data Collection
Data collection will be done in two ways
Quantitative data collection

• Collecting the acceleration figures of the unsprung mass and sprung mass of a light
weight electric vehicle using IMUs.
• Using the data acquired through the DAQ system of a track vehicle.

Qualitative data collection

• Using the questionnaires to identify the strong points and weak points of each
system from the users
Analysing data
Quantitative data will be analysed to identify the specific figures of performance required
thus identifying the technical requirements.
Qualitative data will be analysed to identify the durability and cost expected by the market
for the suggested system.
Using both these analysis feasibility of the system will be evaluated. Parameters that change
the performance and quality of the design will be identified by the data collected.
Identifying aim, scope and objective
Using all the information collected project scope and aim will be decided. Then objectives
will be decided to achieve the required aim and while operating within the scope thus
identifying the parameters that will be changed and optimized under the project.
Concept generation
Few conceptual designs will be formulated by morphological analysis using the objectives
and the collected data.
Selecting the design concept
Best design concept will be chosen by evaluating each concept, weighing according to the
manufacturability, durability, cost and performance.
Developing the design
Kinematic and vibration analysis will be done to identify layout of the system using
SIMULINK.
CAD models will be developed to satisfy the geometric constraints identified by previous
analysis.
Materials will be selected to satisfy the limits of the 3D models and the objectives stated
previously like the manufacturability and the cost.
Fabricating
Manufacturing the system to validate the performance
Validating
Testing the system to validate the performance of the system.
Conclusions
Study the extent to which the aim and objectives of the project are satisfied and comments
for future developments.