Active Suspensions

CEM developed an advanced, electronically controlled suspension system for a variety of military vehicles.  The suspension utilizes motor-driven actuators at each wheel station that applies equal and opposite forces to each wheel to counter the impacts of road obstacles.  Results include the ability to travel over twice as fast on the same terrain with equal, if not improved, ride quality, improved maneuverability and survivability, and reduced likelihood of rollover events, all of which will aid in saving the lives of our troops.

Design / Solid Modeling:

I primarily worked on cargo trucks, which posed unique challenges with their solid axles and leaf spring suspensions.

1. Heavily involved in actuator development, integration and installation on the three generations of suspensions for the Light Medium Tactical Vehicle (LMTV) culminating with the pre-production model.
2. Designed many suspension components, created engineering drawings and followed parts through fabrication both in-house and via outside machine shops.
3. Responsible for the main solid model assembly requiring frequent collaboration with CEM engineers and the vehicle OEM.

Analysis:

1. Utilized Solidworks’ CFD analysis tool, greatly improved fluid flow through the hydraulic actuator reducing frictional losses by 70%, thereby increasing actuator speed.
2. Performed numerous stress and deflection analyses with Solidworks Simulation which guided design.
3. Analyzed buckling cases of the actuator rod under severe shock loading.

Integration & Support:

1. Lead multidisciplinary team to complete integration of three generations of suspensions on the LMTV including other mechanical engineers, electrical engineers, technicians and students.
2. Served as the primary mechanical support engineer during vehicle performance testing at Waterways Experiment Station (Vicksburg, MS) and in Houghton, MI.

Publications:

1. J.H. Beno, M.S. Worthington, and J.R. Mock, “Suspension trade studies for hybrid electric combat vehicles,” SAE 2005 World Congress, Detroit, Michigan, U.S.A., April 11-14, 2005. (PR 372)
2. R.J. Hayes, et al., “Design and testing of an active suspension system for a 2.5 ton military truck,” SAE 2005 World Congress, Detroit, Michigan, U.S.A., April 11-14, 2005. (PR 373)