Lec - 5 Susp Steer Systems

New Cairo Technological University AUTOTRONICS PROGRAM
Faculty of Industry and Energy Technology Suspension & Steering Systems

Ref. Content Possible Activities Resources

General introduction for the main
1 Introduction to the Course Content PowerPoint - Practical Workshop
course titles.
Suspension System Main PowerPoint - Practical Workshop
2 Suspension System
Components.
LO 1
Suspension System Main PowerPoint - Practical Workshop

3 Suspension System
Components.
Air Suspension System Main PowerPoint - Practical Workshop
4 Suspension System
Components.
Circuit Diagram, main Sensors, PowerPoint - Practical Workshop
5 Air Suspension / Electronic Suspension System
and Actuators
Steering System Main PowerPoint - Practical Workshop
6 Steering System
Components.
LO 2
Assisted Steering System Assisted Steering System Main PowerPoint - Practical Workshop
7
Submission of Assignment #1 & IV Components.
Circuit Diagram, main Sensors, PowerPoint - Practical Workshop
8 Resubmission of Assignment #1 & IV
and Actuators
PowerPoint - Practical Workshop
9 Wheels & Tires Wheels & Tyres
LO 3

10 Wheel Alignment Angles Wheel alignment function
11 Wheel Alignment Angles Wheel alignment measurements.
Maintenance and repair of PowerPoint - Practical Workshop
12 Suspension System Maintenance
Suspension Sys.
LO 4
Steering System Maintenance Maintenance and repair of Steering PowerPoint - Practical Workshop
13
Submission of Assignment #2 & IV Sys.
Wheel Alignment testing and Adjustment PowerPoint - Practical Workshop
14 Wheel alignment testing.
Resubmission of Assignment #2 & IV
15 Final Practical Practical Test
16 Final Examination
Page 2
Air suspension is a type of vehicle suspension that is operated by an air pump or compressor that
is either electric or engine-driven. The air is pumped into a flexible bellow, which is commonly
composed of textile-reinforced rubber.
a) Bellow air suspension (Spring)

Rubber bellows make up this sort of spring. For proper
working, the bellows are constructed into circular parts with. As
a result, the coil spring is replaced by a bellows-type air
suspension.
b) Piston air suspension (Spring)

In these types of air suspension systems, a metal-air container in
the shape of an inverted drum is used in this spring. The frame
is attached to the drum, the lower wishbone is coupled to a
sliding piston.
Page 4
An air suspension system generally has

three basic components. They are the air
supply, the airbags, and the height control
valves.
1. Air supply.
2. Airbags.
3. Height control valves.
Page 5
1. AIR COMPRESSOR
A single piston in the air compressor is
moved up and down in the cylinder by a
crankshaft and connecting rod.
The armature is connected to the

crankshaft, and therefore the rotating
action of the armature moves the piston up
and down.
An air dryer that contains a silica gel is mounted on the compressor. This silica gel removes moisture from
the air as it enters the system.
Nylon/Rubber airlines are connected from the compressor outlets to the air spring valves.
Page 6
2. AIR SPRINGS
In an air suspension system, the air springs replace the coil springs in conventional suspension
systems.
The air springs are inflated or deflated to provide a constant vehicle trim height.
Page 7
2. AIR SPRINGS
The solenoid actuators in the struts have up to
four suspension modes that may be selected by
the driver.
1. Comfort—provides a smooth luxurious
ride.
2. Automatic—the suspension computer
provides the best possible combination
of comfort and handling based on speed,
driver style, and road conditions.
3. Dynamic—stiffest, sportiest, most
aerodynamic suspension mode.
4. Life—for rougher roads, steep
approaches, and deep snow. This mode is
used only for low-speed driving.
Page 8
3. HEIGHT SENSORS
Height sensors send an electric signal to the control module in

relation to curb riding height.
There are two front height sensors located between the lower
control arms and the cross member.
A single rear height sensor is positioned between the suspension
arm and the frame.
Each height sensor contains a magnet slide that is attached to the upper end of the sensor.
This magnet slide moves up and down in the lower sensor housing as changes in vehicle trim height occur.
Page 9
Hydro-Active Suspension is a new automotive

technology introduced by the French manufacturer
Citroen in 1990. It describes a development of the
1954 Hydro-pneumatic suspension design using
additional electronic sensors and driver control of
suspension performance.
The driver can make the suspension stiffen (sport
mode) or ride in outstanding comfort (soft mode).
Sensors in the steering, brakes, suspension, throttle
pedal and gearbox feed information on the car's
speed, acceleration, and road conditions to onboard
computers.
Page 10
Advantages Disadvantages
▪ Reduce body roll and pitch ▪ Low Durability & Hight Cost
▪ Lowers the ride height at higher speeds ▪ Heavy and complicated
▪ Slow response
▪ It improves aerodynamic efficiency.
Page 11
In recent years, automobile companies have commercially developed several vehicle models
with semi-active suspension systems. The semi-active suspension system that continuously
adjusts damping levels according to road conditions and vehicle dynamics, such as speed,
turning and cornering, delivering comfort without sacrificing safety and handling.
• Servo/Solenoid valve dampers

• Magnetorheological (MR)/electrorheological (ER) dampers
Page 13
1) Solenoid/Servo valve dampers

A damper consisting of a hydraulic actuator in conjunction with an
electro-hydraulic servo-valve modulating the controlling orifice area.
Solenoid valves do not have as fast or accurate responses as
servo-valves.
The damper is composed of a stepper motor that can help to servo-valve dampers
realize the properties of semi-active control.
Outline of the controller of servo-valve semi-active suspension, and motor installation
Page 14
2) Magnetorheological (MR)
MR damper is a hydraulic damper consisting of a hydraulic cylinder containing micron-sized
particles in an MR fluid (usually oil). MR fluids are non-Newtonian fluids that change their
properties in the presence of a magnetic or electric field.
The time delay in the response of the MR damper was measured and incorporated into the
control.
Page 15
The semi-active suspension controller is designed by processing input data sent by the
acceleration sensors placed on the vehicle body and the suspension position sensors, installed
between the vehicle body and the lower control arms of the suspension system. The position
and acceleration sensors monitor the movements of the wheels and body, and an electronic
control unit realizes the control functionality and manages the necessary communication
between the shock absorbers, the sensors and other control systems in the vehicle.
Page 16
Semi-Active Suspension system layout
Page 17
BODY HEIGHT SENSOR

Body height sensor: The photoelectric body
height sensor is mainly composed of a
photoelectric coupling element, a cover disc, a
shell body, and a protective cover.
ACCELERATION SENSOR
When the wheel slips, the lateral force of the vehicle cannot be
judged correctly by the steering angle and the vehicle speed. At
this time, the acceleration sensor can directly and accurately
measure the longitudinal acceleration of the vehicle and the
lateral acceleration caused by the centrifugal force when the
vehicle
Page 18
STEERING WHEEL ANGLE SENSOR

Steering wheel angle sensor located below the
steering wheel, which is mainly used to detect
the middle positions, rotation directions, rotation
angle and rotation speed of the steering wheel.
VEHICLE SPEED SENSOR

Speed signal is the control signal of an
automotive suspension system commonly used,
and the automobile body roll depends on the
height of the vehicle speed and the size of the
steering radius of the vehicle. The role of the
speed sensor is to detect the car speed.
Page 19
ACTUATOR (SERVO MOTORS)

A motor uses this principle to convert electrical energy into mechanical movement to change the
damper coefficient.
Page 20
Page 21

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New Cairo Technological University AUTOTRONICS PROGRAM

Faculty of Industry and Energy Technology Suspension & Steering Systems

Ref. Content Possible Activities Resources

Suspension System Main PowerPoint - Practical Workshop

PowerPoint - Practical Workshop

a) Bellow air suspension (Spring)

b) Piston air suspension (Spring)

An air suspension system generally has

The armature is connected to the

Height sensors send an electric signal to the control module in

Hydro-Active Suspension is a new automotive

▪ Lowers the ride height at higher speeds ▪ Heavy and complicated

• Servo/Solenoid valve dampers

1) Solenoid/Servo valve dampers

Outline of the controller of servo-valve semi-active suspension, and motor installation

Semi-Active Suspension system layout

BODY HEIGHT SENSOR

STEERING WHEEL ANGLE SENSOR

VEHICLE SPEED SENSOR

ACTUATOR (SERVO MOTORS)

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