A novel space-constrained vehicle suspension mechanism synthesized by a systematic design process employing topology opt
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A novel space-constrained vehicle suspension mechanism synthesized by a systematic design process employing topology optimization Suh In Kim 1,2,3 & Dongil Shin 1,4 & Sang Min Han 1 & Seok Won Kang 1 & Seungmin Kwon 2 & Yong-Sub Yi 2 & Yoon Young Kim 1 Received: 12 March 2020 / Revised: 25 May 2020 / Accepted: 24 June 2020 # Springer-Verlag GmbH Germany, part of Springer Nature 2020
Abstract Demands on larger motors and battery packs in electric vehicles cause a suspension layout issue not appearing in gas-powered vehicles. Motivated by this need, our research aims to design a new-concept suspension applicable to electric vehicles, where given space-related constraints are satisfied without scarifying their kinematic performance. Here, we propose a three-phase design process for the synthesis of rear suspensions of an electric vehicle: concept topology design, kinematic feature identification, and detailed design. For the concept design to determine the mechanism topology, we employ the topology optimization method developed for mechanism synthesis subjected to a reduced suspension design space as well as a tighter condition on the camber rate—known as yielding better vehicle’s dynamic performance. The next phase is to extract the underlying kinematic features of the synthesized suspension obtained by the topology optimization method as it may be difficult to directly figure out how the synthesized mechanism functions kinematically. For the extraction, we propose a connectivity-mapping technique followed by the wrench calculation. This phase is followed by the final detailed design to meet the specific requirements imposed on the target suspensions. The new suspensions designed by the proposed three-phase design approach will be shown to successfully resolve the suspension layout issue typically encountered in electric vehicles. Keywords Topology optimization . Linkage mechanisms . Vehicle suspensions . Electric vehicles . Layout problem . Screw axis theory
1 Introduction 1.1 Literature review on mechanism topology optimization
Responsible Editor: W. H. Zhang * Yoon Young Kim [email protected] 1
Department of Mechanical and Aerospace Engineering & Institute of Advanced Machines and Design, Seoul National University, Seoul, South Korea
2
Research and Development Division, Hyundai Motor Company, Seoul, South Korea
3
Present address: Department of Mechanical Engineering, Massachusetts Institute of Technology, Cambridge, USA
4
Present address: Department of Materials Science and Engineering, Delft University of Technology, Delft, The Netherlands
We begin with the literature review on the topology optimization (TO) method on the linkage mechanism because the mechanism topology optimization method will be employed to find new suspension mechanisms. The TO method was first developed based on a nonlinear bar ground model (Kawamoto 2005; Kawamoto et al. 2004; Stolpe and Kawamoto 2005). Several planar mechanisms designed by the method, such as the converter, inverter, and Peaucellier me
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