Optimization of vehicle suspension systems for improved comfort of road vehicles using flexible multibody dynamics

Methods that account for the flexibility of multibody systems extend the range of applications to areas such as flexible robots, precision machinery, vehicle dynamics or space satellites. The method proposed here for flexible multibody models allows for the representation of complex-shaped bodies using general finite-element discretizations which deform during the dynamic loading of the system, while the gross rigid body motion of these bodies is still captured using fixed-body coordinate frames. Components of the system for which the deformations are relatively unimportant are represented with rigid bodies. This method is applied to a road vehicle where flexibility plays an important role in its ride and handling dynamic behavior. Therefore, for the study of the limit behavior of the vehicles, the use of flexible multibody models is of high importance. The design process of these vehicles, very often based on intuition and experience, can be greatly enhanced through the use of generalized optimization techniques concurrently with multibody codes. The use of sparse matrix system solvers and modal superposition, to reduce the number of flexible coordinates, in a computer simulation, assures a fast and reliable analysis tool for the optimization process. The optimum design of the vehicle is achieved through the use of an optimization algorithm with finite-difference sensitivities, where the characteristics of the vehicle components are the design variables on which appropriate constraints are imposed. The ride optimization is achieved by finding the optimum of a ride index that results from a metric that accounts for the acceleration in several key points in the vehicle properly weighted in face of their importance for the comfort of the occupant. Simulations with different road profiles are performed for different speeds to account for diverse ride situations. The results are presented and discussed in view of the different methods used with emphasis on models and algorithms.