Chassis Systems

Design
AUTE 4070U
Lecture 4

Yuping He
Ontario Tech University
September 14, 2023
3.2 Vehicle Mass Related Parameters Selection
1) Payload, mG
Payload capacity is defined as the maximum mass of
freight allowed.
For trucks, the payload capacity is the difference between
maximum truck weight allowed and empty (or curb) weight
of vehicle (including equipment, fuel, driver, etc.)
For passenger cars, the payload capacity is referred to the
total number of passengers and the allowed luggage.
2) Curb weight/mass, m0
Curb weight is the total weight of a vehicle with standard
equipment, all necessary operating consumables (e.g.,
gas and coolant), a full tank of fuel, while not loaded with
either passengers or cargo.
1.1
 Curb Weight Selections:
1) Comparative Analysis – Based on the same class or level
vehicles’ (samples) parameter (configurations, component
mass, etc.) analysis, determine the required parameter.
2) Ratio of payload and curb weight –  m0 = mG / m0 , in
the case where sample vehicles are not available, this ratio
can be used to determine curb weight for trucks if required
payload is known.
For passenger cars and coaches, the statistics of curb
weight per passenger can be used to estimate the curb
weight.
Statistics of Curb Weight per Passenger for Cars and Buses
Vehicle Subcompact Compact Mid-size Full-size Sub-coach Coach/
Type Car/1000kg Car/1000kg car/1000kg car/1000kg (<30 pass) 1000kg
Curb
weight/ 0.15~0.16 0.18~0.24 0.21~0.29 0.29~0.34 0.096~0.16 0.065~0.13
person 1.2
3) Gross vehicle weight/mass, ma
Gross vehicle weight (GVW) is the addition of vehicle payload
and curb weight.
GVW is the maximum operating weight/mass of a vehicle as
specified by the manufacturer including the vehicle’s chassis,
body, engine, engine fluids, fuel, accessories, driver,
passengers and cargo.
4) Vehicle axle load distribution

1.3
Vehicle Classification based on Gross vehicle weight/mass (North America)

1.4
Vehicle Axle Load Distribution has effects on:
(1) Acceleration performance
Driving axle load allocation determines the tractive force.
(2) Braking performance
Axle load distribution determines braking distance and
braking stability.
(3) Handling characteristics
If neutral steering point is ahead of CG, the vehicle has
oversteer characteristic, otherwise understeer
feature. To ensure some degree of under steer, we have
G2C 1  G1C 2
(4) Tire life span
If an axle is allocated a larger portion of vehicle load, the
wearing of the corresponding tires is heavier than those
of the other axle. It is requested that the load distribution
between axles should be even.
1.5
Axle Load Distribution Determination

For trucks:
(a) cab-ahead-of-engine, front axle load is about 33~35%.
(b) cab-behind-engine, front axle load is about 28%.
(c) worse road and full load conditions, front axle load is
26~27% in order to achieve sufficient tractive force.

For passenger cars, considering handling characteristics:

(a) front engine and front axle driving, front axle full load ~ 55%.
(b) front engine and rear axle driving, rear axle full load ~ 52%.
(c) Rear engine and rear axle driving, rear axle full load ~ 59%

Determining vehicle axle load distribution is not an easy job.

We should consider various factors, such as acceleration
performance, braking performance, handling characteristics,
standard/regulation requirements, and various operating
conditions. 1.6
Recommended Axle Load Distribution for Passenger Cars

Empty Empty Full payload Full payload

payload payload
Powertrain Front axle Rear axle Front axle Rear axle
arrangement
Front engine and 56%~66% 34%~44% 47%~60% 40%~53%
front driving (FF)
Front engine and 50%~55% 45%~50% 45%~59% 50%~55%
rear driving (FR)
Rear engine and 42%~50% 50%~58% 40%~45% 55%~60%
rear driving (RR)

1.7
 Recommended Axle Load Distribution for Trucks
Empty Empty Full payload Full payload
payload payload
Design Front axle Rear axle Front axle Rear axle
arrangement
4x2, single rear 50%~59% 41%~50% 32%~40% 60%~68%
tire
4x2, dual rear 44%~49% 51%~56% 27%~30% 70%~73%
tires, semi-
forward control
cab, cab-
behind-engine
4x2, dual rear 49%~54% 46%~51% 32%~35% 65%~68%
tires, forward
control cab

6x4, dual rear 31%~37% 63%~69% 19%~24% 76%~81%

tires

1.8
3.2 Vehicle Performance Parameter Selection
1) Acceleration Performance
(1) Maximum Speed, Va_max
(2) Power-to-Weight Ratio
Engine’s power output being divided by the weight ( or
mass) of the vehicle, giving a metric that is
independent of the vehicle’s size.
(3) Vehicle acceleration time

2) Fuel Economy
Under good road conditions, full payload, and at direct
gear, consumed fuel in liters per 100 kms, (L/100km)
Number of traveling miles with one gallon of fuel
consumed, (mile/gallon).
For passenger cars:
5.0~10.5 L/100km.
1.9
3) Vehicle Maneuverability
An important measure of vehicle maneuverability is
minimum turning radius, Rmin. It is defined as the
distance of the instantaneous velocity center to the outer
wheel’s trajectory in radial direction. For articulated heavy
vehicles, path-following off-tracking is an important
measure. Swept Path.

L Rmin
1.11
1.12
4) Vehicle Handling Characteristics
(1) Steady State Handling Characteristic
Neutral Steer, Understeer, and Oversteer.
(2) Vehicle Roll Stability

5) Vehicle Ride Quality

(1) Sprung/un-sprung Mass Natural Frequencies.
(2) Suspension Static/Dynamic Deflections.
(3) Tire Dynamic Loads

6) Vehicle Braking Performance

(1) Braking Distance or Decelerations
(2) Braking Stability
(3) Brake Thermal Performance
1.13
4. Vehicle Overall Layout Design
After completing the selection of: 1) vehicle type/model, 2)
vehicle configurations, 3) weights/dimensions, 4)
performance parameters, and 5) overall vehicle dimension
control, the next step is to conduct vehicle overall layout design.
4.1 Main Contents of Vehicle Overall Layout Design
1) Engine (power plant) and driveline arrangement;
2) Selection of suspensions and tires;
3) Arrangement of seats;
4) Arrangement of steering hand-wheel, gas/braking pedals, and
gear-shift lever;
5) Cargo box arrangement;
6) Arrangement of fuel tank and spare tire;
7) Arrangement of interior and exterior of vehicle body;
8) Determining masses of vehicle, assemblies & components;
9) Kinematic analysis for interrelated components/systems.
4.1.1 Engine (Power Plant) Selection
Meeting the following requirements:
1) acceleration performance
2) fuel economy (EPA, NHTSA, the Corporate Average Fuel
Economy (CAFE) program)
3) exhaust emissions and noise. (ECE R15)

1.15
4.1.2 Tire Selection (Bias Tires and Radial Ply Tires)
Considering the following factors:
1) vehicle type/model, e.g., SUV, compact car, race car, etc.
2) applications, e.g., off-road, highway usage, etc.
3) wheel static load and vehicle speed

1.16
4.1.3 Powertrain Arrangement
Considering the following factors:
1) Engine orientation
2) Engine and driving axle relation
3) Propel shaft arrangement

1.17
1.18
1.19
4.2 Drawing for Vehicle Overall Layout
After completing all the steps introduced, a 1:5 drawing for
vehicle overall layout should be made in order to:
1) make the selections and plans into a concrete arrangement;
2) double check selected assemblies’ and components’
configurations, dimensions, masses and performance
parameters. (see if they are aligned with design criteria)
3) find optimal design arrangements.
After the schemes for the overall layout, every assembly and
important component are determined, a 1:1 drawing for overall
dimension control is required, and it is used for:
1) adjust positions, dimensions and orientations of these
assemblies, and components.
2) further validate the dimensions of relevant assemblies and
components.
3) determine the relations of assemblies/components and
their installations on the vehicle.
4) perform kinematic analysis to see if there are motion
1.20
interferences of some components or systems.
1.21
A sample drawing for a car overall layout design

1.22
1.23
1.24
1.25
1.26
4.2.1 Determine Baselines
Important baselines:
1) ground line
2) longitudinal line
3) vertical line
4) front and rear axle lines

1.27
4.2.2 Package Drawings
Considering:
1) ergonomic design
2) seat arrangement
3) interior dimensions
Ergonomic Design

1.28
1.29
Seat Arrangement

1.30
A Sample Design for Seat Arrangement
Interior Dimensions
1.33
4.2.3 Kinematic Analysis
In order to:
1) identify geometric relations between two
components/assemblies
2) double check if there is motion interference
3) provide guidance for detailed design of
components/assemblies.
Identify Geometric Relation

1.34
Inspect Motion Interference

1.35
Provide Guidance for Detailed Design

1.36
1.37