This paper focuses on ZF Sachs' lightweight design strategies for chassis applications - passenger cars dampers and suspension struts - being in integral part in the OEMs roadmap for emission and CO2 reduction. Functional integration and component integration are the key terms when it comes to reducing weight. The relevant strategies fall into three main approaches: lightweight design, lightweight materials and functional integration. In the paper, examples for all three approaches are shown which have different technical maturity - from mass production to advanced engineering study. Starting with intelligent production processes like variable tube wall thicknesses or the partial use of plastic components, the main part describes in detail the concept of an integrated suspension strut & knuckle module based on fiber-composite materials and targeted for use on small cars front axles. Mass production readiness is expected for 2015. The approaches and concepts of ZF Sachs for lightweight dampers and struts have been shown in this paper. A Table summarizes the weight potentials from all different concepts, some of which are already in mass production, some in advanced prototype stage, and others are currently in early development phases. With these concepts, ZF offers the OEM a significant contribution to emission and CO2 reduction.
Development of a fiber-composite suspension strut/knuckle module
Entwicklung eines Federbein/Gelenk-Moduls aus Faserverbundwerkstoff
2010
14 Seiten, 8 Bilder, 2 Tabellen, 7 Quellen
Conference paper
English
Development of a fiber composite suspension strut/knuckle module
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