4.

Suspension

ULSAB-AVC Engineering Report - Appendix - Section 4.0

4.1 Suspension Parts List

ULSAB-AVC Engineering Report - Appendix - Section 4.1

4.1 Parts List - Chassis/Suspension Concepts

ULSAB-AVC Chassis Suspension Concepts
Grade (MPa) Number 13121 13135 Name Assembly Module front axle Subframe complete Bolt M12x40 Sidemember Bolt M14x60 rear Subframe U Pipe Cross member rear Retaining plate Brackets Control arms+radiator Inner frame Outer frame Mounting pipe steering Mounting pipe carbody Weldnut M12 clamp Clamp, transverse leaf spring Bolts M12x25 clamp Leaf spring with support rubber Assembly damper Damper Damper stop spring mod. Rubber for pin bearing Protecting tube Collar nut M8 2. washer Collar bolt M12x60 Steering gear with track rod complete Steering gear with track rod Electric unit for power steering Assembly-lower wishbone Lower wishbone Sleeve joint Rubber mount Ball joint on wheelside with rivets Spring console Collar bolt M12x60 Collar bolt M14x80 Collar nut M12 Collar nut M14 Assembly-upper wishbone Upper wishbone Rubber mount front Rubber mount rear Ball joint Collar nut M12 Collar bolt M12x70 Collar bolt M12x80 Steering knuckle complete Inner shell Outer shell Distance sleeve M10x45 M10x80 M10x35 Collar nut M10 Wheel bearing 2. generation outer ring with flange inner ring 24 balls 10mm diameter Grease Sealing Wheel hub Brakes Assembly front axle brake caliper Front axle brake caliper Collar bolt M10x35 Collar nut M10 Assembly-combined brake caliper rear axle Collar nut M12x25 (2 per caliper) Combined brake caliper rear axle Brake cable left + right parking brake set Actuator electrical parking brake Electro Hydraulic Brake Unit (EHB) Brake Fluid Brake lines front and rear Brake disk front Brake disk rear Drive shafts Assembly-drive shaft left Assembly-drive shaft right Lock-nut Steering column assembly Assembly steering wheel Assembly module rear axle complete Twist-beam rear suspension Trailing arm Twist-beam profile Spring plate Wheel carrier Rubber bushing Collar bolt M14x120 Collar nut M14 Wheel bearing 3.generation Collar bolt M10x25 Spring Damper Protecting tube Damper Collar bolt M12x80 (4 per damper) Wheels Rim Tire Bolts (4 per wheel) Tire Fit Kit Material Type
Yield Strength Tensile Strength Gage (mm) No. of Parts Part Variation Gasoline Diesel Unit

Mass (kg)
Mass of Assembly Unit Gasoline Diesel

GADH Code 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4010 4610

Variation1 Variation 2 Identical 2 2 DP * DP DP DP DP DP 350 350 350 350 350 350 600 600 600 600 600 600 2.0 2.0 2.0 2.0/1.0 2.0 2.0 0.122 0.222 15.738 6.706 0.960 0.023 0.956 1.674 1.214 0.044 0.065 0.030 0.247 0.048 2.300 1.310 1.101 0.011 0.063 0.019 0.007 0.031 0.078 14.150 6.650 7.500 4.256 2.065 0.288 0.156 1.121 0.311 0.098 0.166 0.021 0.032 1.678 0.823 0.146 0.099 0.219 0.021 0.087 0.095 0.989 1.112 0.807 0.044 0.072 0.038 0.012 0.819 0.548 0.143 0.098 0.01 0.02 0.847 4.410 4.310 0.038 0.012 2.918 0.048 2.870 0.713 1.300 5.100 0.500 2.500 7.500 6.600

70.514 17.112

71.514 17.112

15.738

2 2 2 2 2 2 4 2 4 2 Variation 1 Variation 2 Variation 1 Variation 2

13143 13123

GFK

2.300 2.620

2.300 2.620

13125

13171 13173 13175 13177 13179 13181

1 1 1 2 SF 570 640 2.0/1.6

Identical

14.150

14.150

DP

350

600

2.0

LH/RH Identical Identical Identical Identical Identical

8.516

8.516

13183 13185 13187 13189 13191

2 SF 570 600 2

LH/RH LH/RH Identical Identical Identical

3.356

3.356

13161 13163 13165

2 DP DP 350 350 600 600 3.0 3.0 4 2 4 10

LH/RH LH/RH LH/RH

10.332

10.332

13195

2 Forged Steel 2 2 2 1 Aluminium

Variation 1

Variation 2

8.820

8.820

13251 13251 13263 13261 13193

Variation 1

Variation 2

5.836

5.836

4610 4610 4350 4350 4640

Variation 1 Variation 2 Identical Identical Variation 1 Variation 2

Iron Iron

2 2 2

Identical Identical Variation 1 Variation 2

5.100 0.500 2.500 7.500 7.064 3.450 3.400

5.100 0.500 2.500 7.500 8.064 3.950 3.900 5.500 3.500 25.761

13131 13132 13127 13129 13221 13231 13237 13233 13235 13239 13225

2 Identical Identical Variation 1 Variation 2 Identical LH/RH Identical LH/RH LH/RH Identical

0.107 5.500 3.500 20.083 2.85 6.967 0.393 1.035 0.353 0.182 0.032 1.585 0.032 1.505 1.334 0.020 1.124 0.190 10.552 3.720 6.500 0.332 1.000

5.500 3.500 25.761

4210

DP MnB DP DP

350 1200 350 350

600 1600 600 600

3.0/2.2 2.5 2.5 5.0

2 2 2 2 2 2 2 8 2 2

4210

13241 13227 13223

Identical Variation 1 Variation 2 Variation 1 Variation 2 Identical Variation 1 Variation 2 Identical Identical Identical Identical Identical

3.01 2.668

3.01 2.668

4220 4220

13281 13283 13285

1 4 1 1 1

42.208

42.208 4410 4420 4430

* denotes tube

ULSAB-AVC Engineering Report - Appendix - Section 4.1

4.2 Suspension Drawings

ULSAB-AVC Engineering Report - Appendix - Section 4.2

4.2.1 Suspension Drawing Index

Drawing No. 13121 13125 13127 13135 13161 13183 13171 13143 13123 13221 13231 13223

Drawing Name Front Axle Module Steering Gearbox, electrical power supply Steering Column Subframe Steering Knuckle complete Upper Wishbone Lower Wishbone complete Leaf Spring Shock Absorber Front Rear Axle Module Twistbeam Axle Welding Assembly Shock Absorber Rear

13131/13132 Drive Shaft Diesel and Gasoline

ULSAB-AVC Engineering Report - Appendix - Section 4.2.1

4.2.2 Suspension Drawings - Front Axle Module

ULSAB-AVC Engineering Report - Appendix - Section 4.2.2

4.2.2 Suspension Drawings - Steering Gearbox

ULSAB-AVC Engineering Report - Appendix - Section 4.2.2

4.2.2 Suspension Drawings - Steering Column

ULSAB-AVC Engineering Report - Appendix - Section 4.2.2

4.2.2 Suspension Drawings - Subframe

ULSAB-AVC Engineering Report - Appendix - Section 4.2.2

4.2.2 Suspension Drawings - Steering Knuckle Complete

ULSAB-AVC Engineering Report - Appendix - Section 4.2.2

4.2.2 Suspension Drawings - Upper Wishbone Ash

ULSAB-AVC Engineering Report - Appendix - Section 4.2.2

4.2.2 Suspension Drawings - Lower Wishbone Complete

ULSAB-AVC Engineering Report - Appendix - Section 4.2.2

4.2.2 Suspension Drawings - Leaf Spring

ULSAB-AVC Engineering Report - Appendix - Section 4.2.2

4.2.2 Suspension Drawings - Shock Absorber Front

ULSAB-AVC Engineering Report - Appendix - Section 4.2.2

4.2.2 Suspension Drawings - Drive Shafts

ULSAB-AVC Engineering Report - Appendix - Section 4.2.2

4.2.2 Suspension Drawings - Rear Axle Module

ULSAB-AVC Engineering Report - Appendix - Section 4.2.2

4.2.2 Suspension Drawings - Twistbeam Axle Welding Assembly

ULSAB-AVC Engineering Report - Appendix - Section 4.2.2

4.2.2 Suspension Drawings - Shock Absorber Rear

ULSAB-AVC Engineering Report - Appendix - Section 4.2.2

4.3 Suspension Section Forces

ULSAB-AVC Engineering Report - Appendix - Section 4.3

4.3 Suspension Forces - Front Suspension

Front Suspension - Loads on Left Wheel Center
Load Case Vertical Push Steady State Cornering Braking Rearward Braking Forward Acceleration Curbstone Push Acceleration [g] direction 3.4 1 0.9 -1 0.45 0 Forces [N] y 0 0 0 7144 -4755 0 8104 0 -5592 0 0 3572 x Momentum [Nm] y z 0 0 0 2046 0 143 0 1362 0 0 -2321 0 0 0 0 23 0 1704

z 12144 7144 3962 6753 4660 3572

Section Forces
Load Case Vertical Vertical Vertical Vertical Vertical Vertical Vertical Vertical Push Push Push Push Push Push Push Push Mount / Part Lower Wishbone front Lower Wishbone rear Lower Wishbone outer joint Upper Wishbone front Upper Wishbone rear Upper Wishbone outer joint Tie Rod Spring Lower Wishbone front Lower Wishbone rear Lower Wishbone outer joint Upper Wishbone front Upper Wishbone rear Upper Wishbone outer joint Tie Rod Spring Lower Wishbone front Lower Wishbone rear Lower Wishbone outer joint Upper Wishbone front Upper Wishbone rear Upper Wishbone outer joint Tie Rod Spring Mount / Part Lower Wishbone front Lower Wishbone rear Lower Wishbone outer joint Upper Wishbone front Upper Wishbone rear Upper Wishbone outer joint Tie Rod Spring Lower Wishbone front Lower Wishbone rear Lower Wishbone outer joint Upper Wishbone front Upper Wishbone rear Upper Wishbone outer joint Tie Rod Spring Lower Wishbone front Lower Wishbone rear Lower Wishbone outer joint Upper Wishbone front Upper Wishbone rear Upper Wishbone outer joint Tie Rod Spring Acting on Part Body Body Lower Wishbone Body Body Upper Wishbone Steering Rack Lower Wishbone Body Body Lower Wishbone Body Body Upper Wishbone Steering Rack Lower Wishbone Body Body Lower Wishbone Body Body Upper Wishbone Steering Rack Lower Wishbone Acting on Part Body Body Lower Wishbone Body Body Upper Wishbone Steering Rack Lower Wishbone Body Body Lower Wishbone Body Body Upper Wishbone Steering Rack Lower Wishbone Body Body Lower Wishbone Body Body Upper Wishbone Steering Rack Lower Wishbone Fx 1674 -943 829 -664 -166 -830 1 -98 719 -290 514 -407 -101 -508 -6 -85 -6533 -1304 -7742 2393 596 2989 -1 -95 Fx 12479 1625 14062 -4759 -1193 -5951 -7 41 -1916 -535 -2381 -2584 -646 -3231 20 -70 234 -98 187 -121 -31 -152 -35 -51 Fy -8952 1177 -2025 2034 -525 1510 515 -5750 8371 978 12510 -1888 -1306 -3193 -2173 -3161 4466 -6912 -449 -2732 3332 600 -150 -1997 Fy -17620 13061 -1591 6838 -6171 668 923 -2969 -2936 -2057 -2792 3144 -3524 -380 3172 -2201 8483 524 10724 5443 1475 6919 -14070 -1717 Fz -5771 1783 12178 -61 21 -40 6 -16167 -2931 1018 7078 59 38 97 -32 -8992 -2085 424 4022 25 -83 -58 -1 -5683 Fz -2879 1260 6656 -123 193 70 27 -8275 -2311 632 4545 -38 95 57 57 -6224 -1485 559 3959 -125 -34 -159 -229 -4886 Fres 10782 2335 12373 2141 550 1723 515 17159 8899 1441 14383 1932 1310 3235 2174 9531 8183 7047 8736 3632 3386 3049 150 6025 Fres 21783 13221 15639 8332 6288 5989 924 8792 4199 2217 5842 4070 3584 3254 3173 6602 8615 772 11433 5446 1476 6922 14072 5179 Mx Mx My My Mz Mz -

Steady State Cornering Steady State Cornering Steady State Cornering Steady State Cornering Steady State Cornering Steady State Cornering Steady State Cornering Steady State Cornering Braking Rearward Braking Rearward Braking Rearward Braking Rearward Braking Rearward Braking Rearward Braking Rearward Braking Rearward Load Case Braking Forward Braking Forward Braking Forward Braking Forward Braking Forward Braking Forward Braking Forward Braking Forward Acceleration Acceleration Acceleration Acceleration Acceleration Acceleration Acceleration Acceleration Curbstone Push Curbstone Push Curbstone Push Curbstone Push Curbstone Push Curbstone Push Curbstone Push Curbstone Push

ULSAB-AVC Engineering Report - Appendix - Section 4.3

4.3 Suspension Forces - Rear Suspension

Rear Suspension - Loads on Left Wheel Center

Load Case Vertical Push Steady State Cornering Braking Rearward Braking Forward Acceleration Curbstone Push Acceleration [g] direction 3.4 1 0.9 -1 0.45 0 Forces [N] y 0 0 0 8060 -8937 0 5571 0 -8095 0 0 4030 x Momentum [Nm] Mx My Mz 0 0 0 2326 0 161 0 2579 0 0 -1608 0 0 0 0 34 0 1922

z 13702 8060 7447 4643 6746 4030

Section Forces
Load Case Vertical Push Vertical Push Steady State Cornering Steady State Cornering Braking Rearward Braking Rearward Braking Forward Braking Forward Acceleration Acceleration Curbstone Push Curbstone Push Mount / Part Trailing Arm Spring Trailing Arm Spring Trailing Arm Spring Trailing Arm Spring Trailing Arm Spring Trailing Arm Spring Acting on Part Body Wheel Left Body Wheel Left Body Wheel Left Body Wheel Left Body Wheel Left Body Wheel Left Fx 5111 5111 4987 2840 -7922 1014 8396 2825 -4623 3473 3177 1535 Fy -870 -937 7624 -485 -132 -192 -492 -506 -602 -657 3890 -259 Fz 2852 -10850 1653 -6029 5279 -2169 -1345 -5987 -668 -7414 1648 -3262 Fres 5917 12030 9260 6682 9521 2402 8517 6640 4709 8213 5286 3615 Mx My Mz -

ULSAB-AVC Engineering Report - Appendix - Section 4.3