Improving Vehicle Performance and Operator Ergonomics: Commercial Application of Smart Materials and Systems

This paper will discuss how controllable material technology, such as the use of active magneto-rheological (MR) dampers, improves vehicle primary and secondary suspensions. Although relatively new to the marketplace, semi-active suspensions in commercial automobiles and off-highway vehicles have been proven through the use of active MR dampers since 1998. In fact, MR suspension dampers are found today on the commercial vehicles of an increasing number of automotive OEMs and leading off-highway OEMs. MR fluid dampers are simple in design and have the advantage of no moving parts. The resistive force from an MR damper is generated as iron particles, suspended in the magneto-rheological fluid (MR fluid); pass through a magnetic field controlled by the electrical current passing through an electric coil contained within a moving piston surrounded by fluid. By adjusting the current to the damper coil in response to feedback from vehicle sensors and a controller, the damping response of the suspension can be optimized and controlled in real time to provide optimal operator comfort. The MR Damper System has a full-scale step response of less than 10 milliseconds. Sophisticated control algorithms adapt to large changes in payload, enabling the vehicle to meet ride metrics without pneumatic load leveling. Other benefits of the MR damping system include higher speed in NATO double-lane change tests, reduced risk of roll-over, improved accuracy of mounted weapons, and improved vehicle durability and readiness.