Researchers at TU/e have developed an active electromagnetic suspension system that can increase the ride quality of cars by 60 percent. Cars fitted with this suspension system are also safer because they no longer roll (sway) in corners. The system is developed in partnership with the Swedish company SKF.

A demonstration of the new suspension system starts with a striking scene: a standard-looking, dark blue BMW 530i that hops up and down like a ‘lowrider’ in hip-hop video clips. “Of course that isn’t the intention”, explains ir. Bart Gysen, who is working for his PhD on the development of the system. “But it certainly shows what the system can do.” The car’s wheels can be raised and lowered independently in a fraction of a second. And this high speed is one of the most special features of the system. There are already active suspension systems, but these are hydraulic, which means their response is not fast enough to cancel out the rapid vibrations caused by irregularities in the road surface. The new system can do this effectively, which explains the better ride quality.

Vibration-free ambulances
The system developed by Gysen was tested last year on a testbed that simulates road-surface vibrations on just one wheel. That resulted in an increase of 60 percent in ride quality. “We expect that this increased comfort can also be achieved with a real car”, Gysen explains. “And possibly even more, when all four wheels are fitted with the system.” The aim is ultimately to develop more comfortable cars that also have higher safety. This is because the roadholding is improved and the car no longer rolls in bends. For example a car fitted with this suspension system will be much less likely to overturn as a result of abrupt steering maneuvers, such as the slaloming involved in the notorious ‘elk test’. Gysen also believes the system will be attractive for use in ambulances. “An ambulance fitted with this system will be able to transport patients quickly and free of disturbing road-surface vibrations.”

Inherently safe
The system replaces the normal shock absorber in a car, and itself has approximately the same size as a shock absorber. It consists of a passive spring, a powerful electromagnetic actuator, a control unit and batteries. The system is designed to be inherently safe. Even if the electrical power fails, the springing and shock absorbers will continue to work. The passive spring in the system provides springing, and the magnets provide passive, magnetic shock absorption.

Generating power
According to Gysen the system’s energy consumption is modest. “If you install this suspension system on all four wheels, the peak consumption is 500 watt – half of what an air-conditioning system uses. Hydraulic suspension systems use four times as much power. And the consumption of our system can probably be reduced still further by optimization. This is only the first version.” As well as that the system can even use the vibrations from the road surface to generate electricity, which is fed back into the battery.

Coordination
Last month the suspension system was installed on two wheels of a test car for practical tests and further development. One of the tasks is to coordinate the behavior of the active suspension on the individual wheels. At present the separate wheel systems still work independently. SKF, which has financed Gysen’s doctoral research and has also patented the technology, is currently considering whether to market the new suspension system.

AutoRAI
The test car fitted with the new suspension system will be on show at the AutoRAI auto show, to be held from 13 to 23 April in Amsterdam, on the HTAS Automotive Innovation stand number E.01 (Elicium, Auto 2.0). The stand will be manned by personnel who can demonstrate the car and the new suspension system.

Ir. Bart Gysen developed the electromagnetic spring–damper system in the TU/e Electromechanics and Power Electronics group (Department of Electrical Engineering), led by prof.dr. Elena Lomonova. Gysen expects to gain his PhD at Eindhoven University of Technology in 2011.

About Smart Mobility at Eindhoven University of Technology
TU/e has defined strategic areas focusing on the societal challenges in Energy, Health and Smart Mobility. Good mobility is of great importance for individuals, as well as for businesses and the economy. For this reason around 230 researchers from dozens of TU/e research groups are working in the Smart Mobility areas on clean, efficient and intelligent vehicle technology, and on logistics and traffic systems. The aims include reducing emissions and congestion, and increasing safety. Examples of recent developments at TU/e are intelligent cars that communicate with each other to prevent congestion, lighter batteries for electric cars, cleaner and more economical diesel engines, and optimized planning models for goods transport.
As well as research, the TU/e activities in the Automotive field include a Bachelor’s track, a Master’s program and a post-Master’s designer program, the Master’s program in Operations Management and Logistics, and the designer program in Logistics Management Systems.