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FORMULA STUDENT SUSPENSION SYSTEM

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What?

  • Designed and optimized the suspension system for a Formula Student car competing in Formula Bharat, Formula Student Germany, and Formula Student Austria.
  • Focused on reducing the overall unsprung mass, inefficient packaging and compliance(play).
  • Previous version had limited suspension limited tuning options for different track events.
  • Improvement was required in roll stiffness distribution and improper camber gain which resulted in reduced stability and cornering performance.

How?

  • Complete redesign of the suspension geometry by switching from push-rod to pull rod suspension geometry.
  • Developed Kinematic model on Lotus suspension Software.
  • Used Aluminum 6061 for components like bell cranks and anti-roll bars to reduce weight while maintaining strength.
  • Incorporated helical compression springs and DNM Burner RCP2 Dampers with adjustable preload, rebound and compression to handle Dynamic load transfers efficiently.

Result

  • Reduction in the weights of the suspension components by 1.214kg.
  • Enabled dynamic weight adjustment and tuning through optimized pulled rod-length and adjustable dampers.
  • Minimized the overall compliance(play) in the suspension assembly resulting in reduced  vibrations.
  • Winner of Skidpad event and over all Rank of 4th in Formula Bharat 2020.

Project Images

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