ACTIVE SUSPENSION SYSTEM

A Major Project Report

Submitted in Partial Fulfilment of the Requirement for the 5th Semester of Diploma in
MECHANICAL ENGINEERING To

STATE BOARD OF TECHNICAL EDUCATION, PATNA

Submitted by

NAINA KUMARI
Board Roll Number: 511382522052
Registration Number: 1382522052

Under the Supervision of

Lecturer: Mr. KUNAL GAUTAM

Department of Mechanical Engineering

GOVERNMENT POLYTECHNIC SHEIKHPURA

 CANDIDATE’S DECLARATION

I am Naina Kumari student of Diploma (Mechanical Engineering), Government

Polytechnic Sheikhpura, bearing Board Roll Number 511382522052 submit major Project
work entitled ‘ACTIVE SUSPENSION SYSTEM’ to State Board Of Technical Education,
Patna for the Requirement of the 5th Semester of Diploma in Mechanical Engineering and
declaring that the work done is genuine and produced under the guidance of All faculty of
Deptt. Of Mechanical Engineering. .

I further declare that the work reported in this Major project has been submitted for the
Requirement of the 5th Semester as per SBTE, PATNA Curriculum of Diploma in
Mechanical Engineering.

Date: 21-11-2024 Name of Student : Naina Kumari

Place: G.P. Sheikhpura Board Roll No. : 5111382522052
 CERTIFICATE

This is to certify that, this Major Project report titled ACTIVE SUSPENSION
SYSTEM submitted by Naina Kumari bearing Roll Number 511382522052. is
a bonafide record of the Major Project work carried out by him in partial
fulfilment for the requirement of of the 5th Semester as per SBTE, PATNA
Curriculum of Diploma in Mechanical Engineering State Board of Technical
Education at Government Polytechnic Sheikhpura This Major Project has been
submitted to Department of Mechanical Engineering.

Supervisor Head of Department

Mr. Kunal Gautam Mr. Kunal Gautam
(Lecturer) (Lecturer)
Deptt. of Mechanical Engg. Deptt. of MechanicalEngg.
G.P. , Sheikhpura G.P. Sheikhpura
 PREPARED BY :-

1.NAINA KUMARI (2022/M/52)

2. UTTAM KUMAR (2022/M/45)

3. PANKAJ KUMAR (2022/M/46)
4. VISHNU KUMAR (2022/M/50)
5. PRIYANKA RAJ (2022/M/48)
 TABLE OF CONTENT
• 1). Introduction

• 2). Components

• 3). Diagram Of components and working

• 4). Optional configurations:

• 5). Advantages

• 6). Dis-Advantages

• 7). Connection

• 8). Modes of Operation

• 9). Features

• 10). Conclusion

• 11). Application
INTRODUCTION
Introduc on to Ac ve Suspension Ac ve
suspension systems are designed to
enhance ride quality by adjus ng the
suspension characteris cs in real- me.
This technology significantly improves
vehicle handling, stability, and comfort.
Understanding how these systems work is
crucial for apprecia ng their impact on
modern vehicles.
_____________________________________________________________________

Vehicle suspension main task is to

separate passenger and vehicular
body interactions from
oscillations generated by road
abnormalities whilst still maintaining
continuous wheel-road contact.
Currently, there are three types of
automotive suspensions commonly used
namely passive, semi-active, and active
suspension.
 COMPONENTS
The components of an active suspension system include:

1. ACTUATOR OR SERVO

Generates a force that

counteracts the deflec on
caused by road
undula ons, which
improves ride comfort
and reduces vibra ons.

2. CONTROLLER

Part of the controlled suspension

system, which also includes sensors,
plants, and actuators. It uses sensors
and actuators to ac vely control the
suspension of a vehicle.
3 Adjustable shocks and springs:

Ac ve suspension systems
use sensors to monitor the
road and the vehicle's
movements, and then adjust
the shocks and springs to
compensate for bumps, dips,
and other road imperfec ons.

4 Shock Absorbers:

Hydraulic devices that

absorb and control the
impact and rebound
movement of the vehicle's springs and suspensionIt contain a
special fluid that can change its viscosity in response to electric
current.
WORKING OF COMPONENTS

1.ECU
An ac ve suspension system's electronic
control unit (ECU) receives and processes data
from sensors to adjust the suspension se ngs
of a vehicle.

2. Shock Absorbers

A shock absorber is a component of a car

suspension that func ons to dampen up and
down movements or oscilla ons caused by
springs that absorb various shocks or
vibra ons from the road surface.
 3. Dampers
Damper is part of suspension system where it is
func on to prevent noise, bumps, and vibra ons.
Most dampers are categorized in three categories
which is ac ve, semi-ac ve and passive damper.
Magnetorheological (MR) damper is categorized
under semi-ac ve damper.

4. Springs

Springs are a significant component that

has a cri cal role in a car suspension
system. The primary func on of springs is
to absorb or dampen the various shocks
generated from road fric on with car
wheels to not con nue to the car body.

5. Ball Joint

The ball joint is a suspension component that

func ons to accept various lateral and horizontal
loads on the car. The ball joint is also helpful as a
rota on axis when the vehicle is turning. There are
two main types of ball joints, namely upper ball
joints and lower ball joints.
 6. Stabilizer Bar
The stabilizer bar is a car suspension
component that maintains body
balance when the car turns. When
the car turns, it will undoubtedly
create a centrifugal force, which is the
force from an object that turns or
rotates to get out of the track.

CONNECTIONS OF A.S.S.
Ac ve suspension system connec ons refer to the linkages and interfaces that
connect the ac ve suspension components to the vehicle and enable the system
to func on. These connec ons include:

1. Actuator moun ng: Connec ng the actuators to the vehicle's frame or

suspension components.

2. Sensor integra on: Connec ng sensors to the vehicle's suspension and steering
systemfort.

3. Control unit interface: Connec ng the control unit to the vehicle's electrical
system, sensors, and actuators.
 4. Hydraulic or electrical connec ons: Connec ng the actuators to the power
source (hydraulic pump or electric motor).

5. Suspension component connec ons: Connec ng the ac ve suspension

components (e.g., ac ve dampers) to the vehicle's suspension system.

6. Vehicle communica on network: Connec ng the ac ve suspension system to

the vehicle's communica on network (e.g., CAN bus).

7. Power supply connec ons: Connec ng the ac ve suspension system

to the vehicle's power supply (ba ery).

8. Ground connec ons: Ensuring proper grounding of the ac ve suspension

system components.

These connec ons are cri cal to ensure proper func oning, reliability, and
safety of the ac ve suspension system.

Some key considera ons for ac ve suspension system connec ons

include:

- Robustness and durability

- Corrosion protec on
- Electrical noise reduc on
- Secure moun ng and fastening
- Compa bility with vehicle systems
 - Ease of maintenance and repair

By ensuring reliable and efficient connec ons, ac ve suspension systems can

op mize vehicle performance, safety, and comfort.

ADVANTAGES

Improved Ride Comfort

1. Enhanced passenger comfort: Ac ve suspension systems can dynamically
adjust to road condi ons, reducing vibra ons and oscilla ons, providing a
smoother ride.
2. Reduced body roll and pitch: Ac ve suspension helps maintain vehicle
stability during cornering, braking, and accelera on.

Handling and Stability

1. Improved handling: Ac ve suspension adjusts in real- me to op mize re
contact with the road, enhancing grip and stability.
2. Increased stability: Ac ve suspension helps reduce body roll, pitch, and yaw,
improving overall vehicle stability.
Performance
1. Be er trac on: Ac ve suspension ensures op mal re contact, improving
accelera on, braking, and cornering performance.
2. Increased stability during high-speed maneuvers: Ac ve suspension helps
maintain vehicle stability at high speeds.

Safety
1. Reduced stopping distance: Ac ve suspension helps maintain re contact
with the road, improving braking performance.
2. Enhanced stability during emergency maneuvers: Ac ve suspension adjusts
to maintain vehicle stability during sudden turns or evasive maneuvers.

Load Carrying and Towing

1. Improved stability while towing: Ac ve suspension adjusts to compensate
for trailer or load weight, maintaining vehicle stability.
2. Reduced sagging: Ac ve suspension maintains vehicle ride height, even
when carrying heavy loads.
Durability
1. Reduced wear on suspension components: Ac ve suspension can op mize
suspension travel, reducing wear on components.
2. Extended re life: Ac ve suspension helps maintain op mal re alignment
and contact, reducing uneven re wear.
Other Benefits
1. Adjustable ride height: Ac ve suspension allows for adjustable ride height,
useful for off-road or loading/unloading applica ons.
2. Integra on with other vehicle systems: Ac ve suspension can integrate with
electronic stability control, trac on control, and other advanced safety features.

Overall, ac ve suspension systems offer significant improvements

in ride comfort, handling, stability, performance, and safety, making
them a valuable upgrade in modern vehicles.
 DISADVANTAGES
Ac ve suspension systems have several disadvantages, including:

1. : Ac ve suspension systems are complex and require advanced

technology, making them expensive to design, develop, and implement.

2 : The added components and hardware required for

ac ve suspension systems can increase the overall weight of the vehicle.

3. The complexity of ac ve suspension systems can

lead to reduced reliability and increased risk of component failure.

4. : Ac ve suspension systems require

power to operate, which can increase fuel consump on and reduce vehicle
efficiency.

5. Ac ve suspension systems typically have limited travel,

which can restrict their ability to absorb large bumps or shocks.

6. Ac ve suspension systems can generate noise

and vibra on, poten ally compromising ride comfort.
 7. : Ac ve suspension systems require
specialized maintenance and repair, which can be me-consuming and costly.

8. : Ac ve suspension systems rely on

electronic controls, which can be suscep ble to faults or failures.

9. : Ac ve suspension systems require

significant space for components and hardware, which can be challenging in
smaller vehicles.

10. : Ac ve suspension systems require

sophis cated calibra on to op mize performance, which can be difficult and
me-consuming.

11 : Ac ve suspension systems can be difficult to

scale up or down depending on vehicle size and applica on.

12. : Ac ve suspension systems

rely on accurate sensor data, which can be affected by environmental factors or
sensor degrada on.

These disadvantages highlight the challenges and limita ons of ac ve

suspension systems, which must be carefully considered in the design and
development process.
CHALLENGES IN ACTIVE SUSPENSION SYSTEM

1. Cost and complexity

2. Packaging and weight constraints
3. Reliability and durability
4. Control algorithm complexity
5. Sensor accuracy and reliability
6. Actuator response me and
bandwidth
7. Power consump on and
efficiency
8. Noise and vibra on
9. Maintenance and repair
10. Scalability and adaptability
 SOLUTION IN ACTIVE SUSPENSION SYSTEM

1. Advanced materials and design (e.g., lightweight materials, compact

designs)
2. Modular and integrated designs (e.g., combining mul ple func ons in one
unit) 3. Robust and fault-tolerant control algorithms (e.g., using machine
learning or redundancy)
4. High-performance sensors and actuators (e.g., advanced MEMS sensors,
highspeed actuators)
5. Efficient power management (e.g., regenera ve braking, energy harves ng)
6. Advanced noise and vibra on reduc on techniques (e.g., ac ve noise
cancella on, vibra on isola on)
7. Condi on monitoring and predic ve maintenance (e.g., using data analy cs
and machine learning)
8. Scalable and adaptable designs (e.g., modular architectures, reconfigurable
systems)
9. Collabora on and standardiza on (e.g., industry-wide standards, shared
research and development)
10. Con nued research and development (e.g., exploring new technologies,
improving exis ng solu ons)

By addressing these challenges and implemen ng effec ve solu ons, ac ve

suspension systems can become more efficient, affordable, and widely
adopted in various industries.

COST ESTIMATION
Cost estimation in Active Suspension Systems involves
considering various factors, including :

1. Hardware costs:

- Actuators (e.g., hydraulic, electric)

- Sensors (e.g., accelerometers, gyroscopes)
- Control units (e.g., electronic control units, microcontrollers) - Power supply
and transmission components (e.g., ba eries, motors)
- 2. So ware costs:
- Control algorithm development
- Sensor signal processing and fusion - System integra on and tes ng
- 3. System integra on costs:
 - Labor costs for assembly and tes ng
- Integra on with exis ng vehicle systems (e.g., electronic stability control)
- 4. Tes ng and valida on costs:
- Prototype development
- Laboratory and on-vehicle tes ng
- Valida on and cer fica on
5. Produc on costs:
- Manufacturing and assembly
- Quality control and assurance6. Maintenance and repair costs:
- Replacement parts and labor
- Regular maintenance and servicing

Es mated costs for Ac ve Suspension Systems can range from:

- $500 to $2,000 for basic systems (e.g., single-axis control)

- $2,000 to $5,000 for advanced systems (e.g., mul -axis control, semi-ac ve) -
$5,000 to $10,000 or more for premium systems (e.g., fully ac ve,
highperformance)

: These es mates are rough and can vary depending on the specific
applica on, vehicle type, and implementa on.
Ac ve suspension systems have various applica ons across different industries
and vehicles, including :

1. Luxury cars (e.g., Mercedes-Benz,

BMW, Audi)
2. Sports cars (e.g., Ferrari, Porsche,
Corve e)
3. Electric vehicles (e.g., Tesla, Rivian)
4. Autonomous vehicles
5. High-performance vehicles (e.g.,
racing cars)

1. Aircra landing gear

2. Helicopter rotor systems3. Spacecra landing systems

1. Trucks (e.g., semi-trailer trucks, construc on trucks)

2. Buses (e.g., city buses, coach buses)
3. Motorhomes
4. Forestry equipment
1. Material handling
equipment (e.g.,
forkli s, palle zers)
2. Robo cs
3. Industrial automa on
systems

1. Trains (e.g., high-speed

trains, maglev trains)
2. Monorails
3. People movers

1. Military vehicles (e.g.,

tanks, armored personnel
carriers)
2. Military aircra

1. Railroad locomo ves

2. Marine vessels (e.g., ships, submarines)
3. Wind turbines
4. Building suspension systems (e.g., for seismic protec on)
 FUTURE SCOPE
The future scope of Ac ve Suspension Systems is promising, with poten al
developments and applica ons in:

1 Elec fica on : Integra on with electric vehicles and regenera ve braking.

2 Autonomous Vehicles : Enhanced safety and stability for self-driving cars.
3 Advance Materials : Lightweight and high-strength materials for improved
performance.
4 Smart Systems : Integra on with IoT and AI for real- me monitoring and
op miza on.
5 Moduler Designs : Scalable and adaptable systems for various vehicle
pla orms.
6 Energy Harves ng : Regenera ve suspension systems for energy recovery.
7 Advance Control Algoritham : Machine learning and AI-based control
strategies.
8 Sensor Fusion : Integra on of mul ple sensors for enhanced system
performance.
9 Vehicles To Infrastructure connec vity : Communica on with infrastructure
for enhanced safety and efficiency.
10 Nest Genera on Actuators : Advanced actuators with improved
performance and efficiency.