Design and Development of a New Suspension System for the Caterham SV-R

Presented by: Jay OConnell, Multimatic Vehicle Engineering Manager

Vehicle Engineering
Multimatic has engineered a number of complete vehicle and chassis systems for both niche road car and race applications

OEM Sports Car #1

OEM Sports Car #2

Viper Competition Coupe

Panoz LM-GT

Lola B2K/40

Multimatic Ford Focus Daytona Prototype

Caterham SV Suspension

Overview

Presentation Overview Project Scope Project Targets Suspension Design

Suspension Development

Results and Conclusions

Caterham SV Suspension

Project Scope

Project Scope Caterham Cars Ltd. commissioned Multimatic, Inc. to design and develop new front and rear suspensions for the Roadsport SV model in 2003 Revise the front steering geometry and replace the outboard spring-damper design with with inboard mounted dampers maintaining the same motion ratio Replace the de Dion rear suspension with an all new adjustable independent rear suspension

Caterham SV Suspension

Project Targets

Project Targets: Improved ride and handling without losing the iconic character of the Caterham Seven Improved suspension and steering kinematics Increased adjustability (ride height, front ARB, rear camber and toe adjustability) Reduced unsprung weight Minimise use of new components and level of validation required

Caterham SV Suspension

Measurement of Existing Vehicle

CMM measurements taken of existing frame and suspension components

Right front suspension

Left rear suspension

Caterham SV Suspension

Measurement of Existing Vehicle

Chassis compliance was measured through full vehicle torsion testing at MTCE

Caterham SV Suspension

Modeling of Existing Vehicle

Kinematic model of standard car produced in ADAMS and validated based on correlation with K&C results

Caterham SV Suspension

Modeling of Existing Vehicle

SDRC I-Deas 3D CAD models were created for the existing components and assembled into a full vehicle model

Caterham SV Suspension

Target Setting

Front and Rear suspension design targets were set using desired vehicle characteristics, benchmarking and experience
Front Targets Caster (deg) Caster trail (mm) KPI (deg) Hub offset (mm) ground offset (mm) Toe (deg) Camber (deg) Roll Centre H (mm) RC migration @3(mm) Anti-Dive (%) Anti-Squat (%) Anti-Lift (%) Bump Steer (deg/m) Bump Camber (deg/m) Bump Caster (deg/m) Wheel Reces. (mm/m) Roll Camber (deg/deg) Roll Steer (deg/deg) Ackerman (%) 5.0 30.0 9.0 to 11.0 50.0 to 60.0 8.0 to 15.0 -0.10 -2.00 30.0 to 40.0 -10.0 to 10.0 20.0 -3.0 to 5.0 -10.0 to 40.0 < 20.0 > 0.0 0.25 to 0.30 0.04 to 0.075 40.0% Rear Targets 2.0 to 5.0 5.0 to 25.0 <12.0 40.0 to 75.0 -5.0 to 20.0 0.17 -1.25 20.0 to 40.0 > Front 5.0 to 15.0 < Front 20.0 40.0 1.0 to 2.5 -10.0 to -40.0 Minimise >15.0 0.35 to 0.40 -0.01 to -0.02 -

Caterham SV Suspension

Optimisation
54373 - Caterham SV
SV geometry targets

Kinematics optimised using ADAMS/Car and ADAMS/Motorsport against baseline targets Proposals reviewed and compared against CAD data for design and manufacturing feasibility

FRONT SUSPENSION
Proposal C: Objectives: Widen the front track to correspond to the rear one Constraints: Use the existing upright, hub, lower A-Arm position Modifications: Hub shifted outboard to match new front track.

June 17, 2003

Front Suspension TARGET Caster (deg) Caster trail (mm) KPI (deg) Hub offset (mm) ground offset (mm) Toe (deg) Camber (deg) Roll Centre H (mm) RC migration @3(mm) Anti-Dive (%) Anti-Squat (%) Anti-Lift (%) Bump Steer (deg/m) Bump Camber (deg/m) Bump Caster (deg/m) Wheel Reces. (mm/m) Roll Camber (deg/deg) Roll Steer (deg/deg) Ack erman (%) 5 30 9 to 11 50 to 60 8 to 15 -0.1 -2.0 30 to 40 -10 to 10 20 -3 to -5 -10 to -40 <20 >0 0.25 to 0.30 0.04 to 0.075 40% SV original 7.7 33 11.2 100 61.5 -0.28 -2.3 62 -0.9 72 -1.6 -30 39 9 0.39 0.02 32% (1 rev) Proposal B 4.7 24 10.9 75 36.5 -0.33 -2.1 32.2 -3.6 57 -4.0 -17 29 2.2 0.22 0.05 33% (1 rev) Proposal C 4.8 24 10.9 75 36.5 -0.34 -2.1 33 -4.1 57.6 -4.2 -17 29 1.9 0.22 0.05 32% (1 rev)

* All values valid for ride height 2UP condition with CR500 195/45 R15 tyre.

Caterham SV Suspension

Kinematic Analysis

ADAMS example: Front Roll Analysis

Caterham SV Suspension

Kinematic Analysis

ADAMS example: Rear Roll Analysis

Caterham SV Suspension

New Design Modeling

Full chassis and suspension 3D solid modeled in SDRC I-deas

Caterham SV Suspension

New Design Modeling

Component design reviewed in partnership with Caterham and their suppliers

Caterham SV Suspension

Component Design

Component designs created from 3D hardpoints

New rear cast upright

Caterham SV Suspension

Component Design

Component designs optimised using load cases generated from the ADAMS analysis

Topology optimisation of the front rocker

Caterham SV Suspension

Component Design

Design verification using FEA on critical components

ABAQUS stress analysis of the front rocker design under a 5g loadcase

Caterham SV Suspension

Initial Set-Up Calculations

Initial suspension set-up calculation for spring and bar rates performed using Multimatic software

Caterham SV Suspension

Initial Set-Up Calculations

Initial damper forces calculated using Multimatic Dynosoft software

Caterham SV Suspension

Dynamic Analysis

Virtual 4-Post Rig Analysis

Caterham SV Suspension

Prototype Assembly

Build support at Caterhams Dartford, UK factory

Caterham SV Suspension

K+C Rig Test

Suspension kinematics and compliances measured on single axle K+C rig and compared with ADAMS analysis

Caterham SV Suspension

4-Post Rig Test

Vehicle tuned on MTCE 4-post rig in Thetford, UK using Dave Williams methodologies

Caterham SV Suspension

Road Testing

Initial road testing at Millbrook conducted by Murray White, Head of Vehicle Development:

Very Impressive performance out of the box; greatly reduced steering effort, kickback, and rear-end steer over bumps. Limit balance was progressive and adjustable and proved sensitive to anti-roll bar stiffness changes. The yaw center seems about right for a good compromise between agility and stability. Good phasing of the front to rear axle lateral force build up.

Caterham SV Suspension

Track Testing

On-track development run and supported by MTCE staff: engineers, technicians and driver

Snetterton Test: 13th September 2003. Driver: Scot Maxwell

Caterham SV Suspension

Track Testing

On-track development run and supported by MTCE staff: engineers, technicians and driver

The new suspension makes the vehicle more stable and easier to drive faster. Scott Maxwell, Driver

Caterham SV Suspension

Results

Program results: Project managed and delivered on time to Caterham Incorporated increased level of adjustability 6 kg reduction in unsprung mass Improved kinematics:
lower roll centre both front and rear significant reduction in hub and ground offset Improved wheel recession and front/rear anti-dive/ anti-lift balance

Ride and handling: the car was very good right out of the box. The steering feel and response was improved and the handling was well balanced, progressive and adjustable.

Caterham SV Suspension

Conclusions

Conclusions: Successful integration of target setting, analysis, rig testing and road testing Front and Rear suspension systems designed to complement each other Modern platform for Caterham future derivatives