Electronically Controlled Air Suspension System (ECASS

Electronically Controlled Air Suspension System
1. INTRODUCTION
Today we are living in the world of science and technology. Today's
technology is becoming past and tomorrows is struggling for it's existence.
Automobile engineering is also fastest growing field. The automobile
suspension provides ground for extensive research and development.
Conventional suspension systems such as leaf spring, coil spring
suspension lack prime requirement of variable spring rate for various load
conditions thus giving less vehicle controllability and passenger comfort.
Consumer's satisfaction is a keyword in today's business. So
scientists and engineers have developed an air suspension system which
provides more comfort and better vehicle controllability.
I have started this seminar with critical review of conventional
suspension systems, their drawbacks and alternative provided by air
suspension. I have described general arrangement of air suspension system
and its components and their functions.
The second part deals with air-suspension system and is electronic
control. Since active suspension is an advanced part comprising of model
prototype studies and extensive force analysis on chassis and complex
mathematics, I have avoided that Instead I have focused on sensors used in
electronic suspension and design parameters, to be controlled electronically.
At the end there is a distinct comparison between the conventional
construction, I hope that air suspension will be a common feature of future
Indian vehicles.
J.T.Mahajan Polytechnic College, Faizpur
The basic function of an automobile suspension is to isolate passenger

from shocks and vibration. Road surface decides forces acting on vehicle
chassis and resulting vibrations. Various suspension systems with different
arrangements are used to perform the function.
1.1
THE SUSPENSION SYSTEMS IN AUTOMOBILES CAN BE

DIVIDED TWO MAIN PARTS
a)
Rear Suspension system and
b)
Front suspension system.
a)
Rear Suspension System
Functions
i)
To support rear weight of vehicle.
ii)
To isolate vehicle pay load from shocks and vibrations.
b)
Front suspension system

In addition to functions described above front suspension system has
to perform two more functions.

i)
To provide steering control and wheel alignment.
ii)
To maintain steering control during severe braking.

Before going into air suspension system let us see conventional
suspension systems.
1.2
CONVENTIONAL SUSPENSION SYSTEM

It consists of coil spring, torsion bars, leaf springs.
1)
Leaf springs
Widely employed in trucks and cars in India.
2)
Torsion bars
e.g. pugeuot (America)
3)
Machperson strut
Widely used in front suspension system.
2.
NEED OF AIR SUSPENSION
2.1
MAIN DRAWBACKS OF CONVENTIONAL SYSTEMS
1)
Rear Wheel Bounce

Experienced on laden and unloaded trucks, trailers, causing driver
fatigue, noise, excessive tyre wear and punishing structural stresses.

2)
Uncomfortable Pitching
On lightly laden buses and trucks causing passenger discomfort or
damage to fragile freight and chassis components.

3)
Change in Headlight Angle

Occurring on partly laden trucks, causing awkward misalignment
between trucks and loading platform.

4)
Load Imbalance
Occurring on partly loaded trucks, causing awkward misalignment
between truck's loading platform.
2.2
HISTORY OF AIR SUSPENSION SYSTEM

The idea of suspending a vehicle on air goes back over 100 years in
the mid of 19th century.

Many experiments were carried out but the absence of a durable
rubber material for air springs severely limited development.
It was only in 1980's when air -springs were successfully introduced in
automobiles. Experiments are still going on to optimise smooth ride and
comfort.
3. AIR SUSPENSION SYSTEM AND COMPONENTS
Micro computer
Air spring
Fig. 1: Air suspension system & its components
3.1 AIR SPRINGS

Generally air spring is incorporated at each wheel.
a) Types
1)
Single convolution
2)
Double convolution
3)
Triple convolution
4)
Rolling diaphragm type
5)
Un-restricted diaphragm type 6) Rolling lobe spring.
Working
Air flow in spring is controlled by levelling valve so as to change spring
rate of spring to suit load conditions.
To prevent any damage to spring, a guard is provided.
3.2
LEVELING VALVE
a)
Levelling valves are used to maintain constant platform height by

controlling the passage of air to and from the air-springs.
Three valves are used, one control mounted above the front axle
controlling front springs and one mounted above each end of v-frame
controlling the respective springs.
b)
Operation of valve
Levelling valve is a three way valve

1)
Compressed air supply to valve
2)
Compressed air supply to spring
3)
Exhaust
3.3
ISOLATOR VALVE
It's function is to prevent loss of roll stiffness whilst cornering. This is
accomplished by restricting the transfer of air from one spring to other except
when air is being admitted to exhaust from springs due to activation of he
levelling valve.
3.4
AIR FILTER
It is in-corporate between auxiliary reservoir and levelling valve. Sintered
bronze filters are fitted in the valve ports to protect the internal mechanism from
damage by foreign matter which may be carried back from the interior of the
spring.
3.5
DRIER
Any moisture in the air in air-spring will corrode the interior of the spring.
Hence drier is fitted in suspension air ckt. It contains silica gel which absorbs
moisture from air. Exhaust air from air spring is used as a re-generative agent to
remove moisture from silica gel and make it fresh.
3.6
PRESSURE REGULATOR
It is connected in the pipe line from the auxiliary reservoir, safeguard the
braking system by allowing air into suspension system only when sufficient
pressure is available in the braking system.
3.7
COMPRESSOR
It is connected to storage reservoir. It is operated from engine. There is a
single air for air-brake and suspension system.

In some cars e.g. Nissan motors D.C. motor is used to drive compressor.
4. TWO BASIC TYPES OF AIR SUSPENSION SYSTEMS

1)
The brake installation and air suspension have the same container
pressure. The suspension is coupled secondary to the brake installation.
2)
Air suspension operates at higher pressure than the brake installation.

The compressed air from brakes is taken directly after the frost protection
pump and before the four way safety valve. The overflow valve from the
braking has a higher opening pressure than safety valve in order to
safeguard priority of the brake system.
4.1. BASIC PRINCIPLES OF AIR SPRING ARRANGEMENT

1)
All air suspension on guided wheels

It is clear that any irregularities in road surfaces causing vibrations are
directly related with spring-rate. In this case air spring rate determines natural
frequency of the vehicle directly.
2)
All air suspension with swinging axles

The forces on the wheel and on the air spring work on different lever arms.
For this reason forces and deflections of different magnitude act on the
wheel and on the air spring. In order to determine the natural frequency of
vibration; reduced spring are must be determined at the wheel Centre.
5. ELECTRONIC CONTROL OF AN AIR SUSPENSION

SYSTEM
5.1. NECESSITY
Spring rate and damping coefficient need accurate settings so as to give
better ride performance.
Road conditions are prime factors which affect socks and vibrations. By
use of sensors and feed-back loop control, pre-programmed micro-processor can
perform accurate control of air suspension ckt.
Hence to achieve better vehicle controllability and ride comfort electronic
control is employed.
5.2
CONTROL SYSTEM
In incorporates electronic sensors and micro-processor unit.
5.3
COMPONENTS
OF
ELECTRONICALLY
CONTROLLED
SUSPENSION SYSTEM
a)
AIR SUSPENSION UNIT

Shock absorbers and air spring are designed with integrated construction.
A small motor built into the piston rod operates a control valve which
varies damping coefficient over-three different settings (described later).

The front suspension unit has taper rolling guide in order to give the spring
rate a suitable no linear characteristics.
b) SUB-TANK
It is equipped at each wheel. When low spring rate is desired a portion of
the air in the air spring is divided into the sub-tank.
The structure is as follows
1)
The supply valve controls inflow and outflow of air for regulating
the
vehicle height.
2)
The cut-off valve controls the flow of air between the suspension unit and
sub-tank to select the proper spring rate. It also incorporates a valve that
functions to maintain a minimum pressure level in the chamber.
It also prevents a vacuum from developing in the chamber when the
suspension unit is fully extended.
c)
COMPRESSOR
Similar as explained earlier. In addition a thermostat is provided which
stops the operation of the compressor if the humidity inside the compressor goes
above certain level.
d)
PRESSURE SWITCH
It maintains pressure inside piping below 10 kgf/sq.cm.
e)
VEHICLE HEIGHT SENSOR

3 in no.2 at front suspension unit. 1 at rear unit.
It is equipped with potentiometer that provides reading in increment of 1
mm allowing fine tuning.
f)
STEERING ANGLE SENSOR

For accurate detection of straight line condition of the vehicle .
Neutral position sensor is added to steering angle sensor. This prevents
any Un-necessary vehicle pitching by temporarily suspending the vehicle
height control when vehicle is turning.
g) Warning Lamp
When the control module senses a system defect, the module turns
on the air suspension warning lamp in the roof console to inform the driver
that a problem exists. If the air suspension system is working normally, the
warning lamp will be on for one second when the ignition switch is turned
from the Off to the Run position. After this time, the warning lamp should
remain off. This lamp does not operate with the ignition switch in the start
position. The warning lamp is used during the self-diagnostic procedure
and the spring fill sequence.
6. CONTROL UNIT
It consists of
1)
Micro-computer
2)
Power supply
3)
Analogue to digital converter
4)
Input signal circuits
5)
Actuator for damping coefficient selection and drive circuit for each valve.
6.1
MICRO-COMPUTER FEATURES
1)
8-bit processor
2)
ROM - 13 KB
3)
RAM - 252 Byte

The program is designed with good compatibility between control and
timing requirement.
The electronic ckts. make extensive use of FET's and transistors with bilt
in surge absorber. This results in lower ckt costs and improved packing density.
Fail safe function and self diagnostic functions are also added.
Fail safe system suspends control over the symbolic system of the
affected device, wile maintaining he maximum control possible over other
systems so as to assure safe operation.
7. COMPARISON OF AIR SUSPENSION SYSTEM &

CONVENTIONAL SUSPENSION SYSTEM
Sr.
No.
1.
2.
Parameter
Air Suspension
Conventional
Load Carrying Capacity

Ability to Absorb Shocks &
Higher
Better
Suspension
Lower
Good
3.
4.
Vibrations
Car Height Control
Squat
Dive
&
Better
Better
No
Poor
5.
6.
7.
8.
9.
10.
Characteristics
Cost
Maintenance
Passenger Comfort
Electronic Control
Life
Noise Level
Costly
More
Excellent
Possible
More
Less
Cheaper
Less
Not Satisfactory
Not possible
Less
Higher
Roll
8. CONCLUSION
From the critical comparison of suspension systems, it becomes clear that

air suspension system provides a better alternative for conventional system
ensuring better car ability and better passenger comfort.
The requirement of this suspension system is better road conditions.
With improvement in road conditions, I hope that air suspended vehicles

will be a common feature of future Indian vehicle.
REFERENCE1)
Course & Anglin, Automotive Mechanics,

by: McGraw Hill Publication (1991)
2)
Ellinger, H.E., Automobile Chasis and Design
3)
Dunlop, Pneuride, Technical Information Manual, (1990)
4)
Journal of Air-Suspension and Shock Absorbers, Wheels and Tyres (1990)
5)
R. Bosch VOT-KKB 1011, Leveling valves for air

commercial vehicles. (1994)
suspension on
SYNOPSIS
In this paper. I have tried to give details about advanced suspension

system which is nothing but air suspension system and its advantages over
conventional system.
It includes details about air suspension systems, its types, components

of system and electronic control of air suspension system which used to control
the different specifications of suspension system and lastly comparison between
air suspension system and conventional suspension system.
CONTENTS
SYNOPSIS
1.
2.
3.
4.
INTRODUCTION
1.1
Types of Suspension System
1.2
Conventional Suspension System
NEED FOR AIR SUSPENSION

2.1
Main Drawback of Conventional System
2.2
History of A.S.S.
A.S.S. AND COMPONENTS

3.1
Air Spring
3.2
Levelling Valve
3.3
Isolator Valve
3.4
Air Filter and Drier
3.5
Pressure Regulator and Compressor
TWO BASIC TYPES OF A.S.S

4.1
5.
Basic Principles of Air Spring
ELECTRONIC CONTROL OF A.S.S.

5.1
Necessity
5.2
Control System
5.3
Components of Electronically Controlled S.S.
10
6.
CONTROL UNIT
14
7.
COMPARISON OF A.S.S & CONVENTIONAL S.S.
15
8.
CONCLUSION
16
REFERENCE
17

Electronically Controlled Air Suspension System (ECASS

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Electronically Controlled Air Suspension System

J.T.Mahajan Polytechnic College, Faizpur