Advanced Chassis Systems Report

SupplierBusiness

Contents

Introduction ........................................................................................................................ 7 Increasing influence of electrification ............................................................................ 8 Chassis performance ....................................................................................................... 9

Design compromise ..................................................................................................... 9 Manufacturing economics ......................................................................................... 10 Platform development and component commonality .............................................. 11 Noise vibration harshness ........................................................................................... 12

Key Development drivers .................................................................................................. 13 Greenhouse gas emissions and fuel efficiency .............................................................. 13

Noise vibration harshness ........................................................................................... 13 Chassis materials developments ................................................................................... 20 Increasing electrification ............................................................................................... 25

Systems integration .................................................................................................... 25 The packaging dilemma ................................................................................................ 27 The future for chassis design ........................................................................................ 28

Suspension systems ........................................................................................................... 30 Challenges and barriers ................................................................................................. 33 Suspension developments: passive on its way to active .............................................. 35 Kinematics and elastokinematics ................................................................................. 37 Suspension element technology ................................................................................... 38

Control arms............................................................................................................... 38 Spring systems ............................................................................................................ 41

Active body control ....................................................................................................... 45 Anti-roll bars .............................................................................................................. 47

Adaptive damping system ............................................................................................. 48 Air suspension ............................................................................................................... 48 Active suspension ........................................................................................................... 51

Electronic Damper Control (EDC) ............................................................................. 51 Active Suspension Geometry (ASG) .......................................................................... 52

Semi-active suspension ................................................................................................. 52 Active electronic suspension system ............................................................................ 53 Future trends ................................................................................................................. 54

Advanced Chassis Systems Report

© 2011 IHS Inc. 3

Steering systems ................................................................................................................ 55 Electrically Power Assisted Steering (EPAS) ................................................................ 55

Surface acoustic wave ................................................................................................ 57 Software enabled features .......................................................................................... 58

Electro-Hydraulic Power Steering (EHPS) ................................................................... 59 Electric Power Steering (EPS) ....................................................................................... 59 Steer-by-wire ................................................................................................................. 61 Active Front Steering (AFS) .......................................................................................... 62 Four-wheel steering ....................................................................................................... 65 Automated parking ....................................................................................................... 65

Braking system development ........................................................................................... 67 Anti-Lock Braking System (ABS) .................................................................................. 67 Electronic Braking System (EBS) or Electronic Brake Distribution (EBD) ................. 68 Brake Assist (BA) ........................................................................................................... 68

Mercedes-Benz SBC – an advanced mechatronic system ......................................... 68 Autonomous emergency braking ............................................................................... 71

Ceramic composite brakes ............................................................................................. 71 Brake-by-wire ................................................................................................................ 72

Electro-hydraulic brake-by-wire................................................................................ 72 Electro-mechanical brake-by-wire ............................................................................ 73

Regenerative braking systems and brake blending ...................................................... 75 Vehicle stability systems ............................................................................................... 77

Four-wheel drive (4WD)................................................................................................... 79 Emissions and Fuel Economy .................................................................................... 79

Active Torque Dynamics (ATD) ................................................................................... 80 Safety and AWD ......................................................................................................... 80 Technologies and Challenges .................................................................................... 82

Electric AWD ................................................................................................................. 83 Integration of Control Systems.................................................................................. 83

Active All Wheel Drive (AWD) ..................................................................................... 83 Torque vectoring ........................................................................................................... 84 Future trends ................................................................................................................. 85

Chassis and corner modules ............................................................................................. 86

Advanced Chassis Systems Report

© 2011 IHS Inc. 4

Supplier Profiles ................................................................................................................89

Algat Industrie SRL .......................................................................................................89 Autoliv ............................................................................................................................ 91 Benteler .......................................................................................................................... 93 Bharat Forge...................................................................................................................96 Bosch ..............................................................................................................................99 Brabant Alucast ........................................................................................................... 104 BWI Group .................................................................................................................... 105 Continental ................................................................................................................... 107 iextic .............................................................................................................................. 114 JTEKT Corporation ....................................................................................................... 116 KYB ................................................................................................................................ 119 Magna/Cosma International ........................................................................................ 122 Magneti Marelli ............................................................................................................ 126 Mando ........................................................................................................................... 130 Mubea ........................................................................................................................... 133 NSK ............................................................................................................................... 134 Schaeffler ...................................................................................................................... 137 Sogefi ............................................................................................................................. 141 tedrive Steering ............................................................................................................ 144 Tenneco........................................................................................................................ 146 ThyssenKrupp .............................................................................................................. 149 Tower International ..................................................................................................... 154 Trelleborg ...................................................................................................................... 157 TRW Automotive.......................................................................................................... 161 VB-Airsuspension ......................................................................................................... 170 WABCO ........................................................................................................................ 172 ZF Friedrichschafen ...................................................................................................... 177

Advanced Chassis Systems Report

© 2011 IHS Inc. 5

List of Tables and Figures Table 1: Front axle design proportions, worldwide light passenger vehicles (%) ........... 40 Table 2: Front axle design by segment, worldwide light passenger vehicles (%) ........... 41 Table 3: Rear axle design proportions, worldwide light passenger vehicles (%) ............ 41 Table 4: Rear axle design by segment, worldwide light passenger vehicles (%) ............ 42 Figure 1: Conventional suspension compromises .............................................................. 9 Figure 2: The complex functional harmony required to provide driving quality ........... 10 Figure 3: Matching and similar parts for the Volkswagen B/C platform ......................... 11 Figure 4: Common and matching parts (Chassis, drivetrain, steering system) for the Volkswagen B/C platform .................................................................................................. 12 Figure 5: Current European progress in CO2 emissions ................................................... 13 Figure 6: CO2 Improvement Rate (Base Year 2004) ......................................................... 15 Figure 7: Average fuel efficiency 2010 and 2015 targets for gasoline vehicles ................. 14 Figure 8: US vehicle trends 1975 – 2009, fuel economy, power, weight.......................... 18 Figure 9: US Transportation Sector emissions scenarios ................................................ 19 Figure 10: Weight share of modules and their weight increase ...................................... 20 Figure 11: Cost comparison of lightweight vehicle structures .......................................... 21 Figure 12: Financial punishments for extra grams ........................................................... 22 Figure 13: Average profit per vehicle versus CO2 compliance costs ................................ 23 Figure 14: The growth of integrated functions ................................................................. 24 Figure 15: The relationship between functions and control units to 2014 ...................... 26 Figure 16: X-by-wire roadmap .......................................................................................... 27 Figure 17: Conventional suspension compromises .......................................................... 30 Figure 18: Ford Focus control blade suspension .............................................................. 32 Figure 19: Suspension control arm configurations .......................................................... 38 Figure 20: Typical control arm designs ............................................................................ 39 Figure 21 Continental’s air suspension system ................................................................. 43 Figure 22: Continental's air suspension system ............................................................... 50 Figure 23: Bose's fully electromechanical front suspension model ................................. 53 Figure 24: Column mounted electrical assist ................................................................... 56 Figure 25: Paraxial electrically assisted rack .................................................................... 56 Figure 26: The interior of GM’s Hy-wire concept vehicle ............................................... 61 Figure 27: Components of an active system ..................................................................... 62 Figure 28: Active steering system components ............................................................... 63 Figure 29: Variable ratio steering. .................................................................................... 64 Figure 30: Renault’s active four wheel steer systems as fitted to the Laguna GT ...........66 Figure 31: Continental’s electro-hydraulic combi braking system layout ....................... 74 Figure 32: Continental’s electronic wedge brake on test ................................................. 75 Figure 33: Continental’s regenerative braking system layout.......................................... 76 Figure 34: TRW’s second generation slip control boost brake technology. ................... 75 Figure 35: Bosch's yaw torque compensation system. ..................................................... 77 Figure 36: Attributes of lifestyle and AWD wagons and performance AWD vehicles ... 81 Figure 37: Attributes of SUVs and crossover vehicles ..................................................... 81 Figure 38: BWI’s corner module ....................................................................................... 86 Figure 39: MOBIS’ front chassis module .......................................................................... 87 Figure 40: MOBIS’ rear chassis module ........................................................................... 88

Advanced Chassis Systems Report

© 2011 IHS Inc. 6