Design and analysis of a hydro-pneumatic suspension system

Suspension systems are generally one of the most critical components for the ride dynamics and comfort performance of a vehicle. Also, off road performance and mobility of the high tonnage vehicles directly depend on the suspension system of the vehicle. In this thesis study, firstly displacement and velocity equations have been derived by using the kinematics of the hydro-pneumatic suspension unit (HSU) mechanism. Furthermore, the input and output parameters have been specified to design an HSU and necessary parametric equations have been derived which related with the input and output parameters. By using the derived equations, a graphical user interface (GUI) has been developed which enables the user to easily design different configurations of an HSU. Then, by using the predetermined input parameters and developed GUI, detailed design of the system and the 3D CAD model of a hydro-pneumatic suspension system have been performed. Bill of materials, manufacturing and assembly drawings have been prepared for the designed system. Also, structural finite element analysis have been performed for the worst case loading conditions of the system and finite element analysis results have been compared with the GUI output results. Finally, technical data package have been prepared for the designed HSU.