Design, modelling and experimental validation of a composite suspension system for solar EVs

IF 7.1 2区材料科学 Q1 MATERIALS SCIENCE, COMPOSITES

Composite Structures Pub Date : 2025-09-17 DOI:10.1016/j.compstruct.2025.119650

Ana Pavlovic, Giangiacomo Minak

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引用次数: 0

Abstract

This study presents the design, finite element modeling, and experimental validation of a novel rear suspension system for lightweight, solar-powered electric vehicles. The proposed system features stiffness-tunable components made entirely from carbon fiber-reinforced polymers (CFRPs), including a torsion bar and flexural springs engineered to maximize the strength-to-weight ratio while ensuring fail-safe operation. This work represents one of the first fully integrated efforts to design, simulate, and validate a complete CFRP-based suspension system tailored for solar vehicle applications, with specific attention to redundancy and reliability. A multilayer layup strategy is adopted to customize the mechanical response under vertical, lateral, and torsional loading. Finite Element (FE) analyses using layered shell elements are conducted to assess stress distributions and identify potential failure zones, employing the Tsai–Wu failure criterion. Experimental testing confirms the accuracy of the numerical predictions, with stiffness deviations below 10% under representative loading conditions. The results demonstrate the feasibility of using anisotropic CFRP laminates to achieve compact, efficient, and reliable suspension systems with stiffness-tuning capabilities. The proposed approach offers a validated design methodology suitable for long-distance solar vehicle competitions, where weight, safety, and operability under partial damage are critical.

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太阳能电动汽车复合悬架系统的设计、建模和实验验证

本研究介绍了一种新型轻型太阳能电动汽车后悬架系统的设计、有限元建模和实验验证。该系统的特点是刚度可调部件完全由碳纤维增强聚合物（CFRPs）制成，包括扭力杆和弯曲弹簧，旨在最大限度地提高强度重量比，同时确保故障安全运行。这项工作代表了为太阳能汽车应用量身定制的基于cfrp的完整悬架系统的设计、模拟和验证的首次全面集成工作之一，特别关注冗余性和可靠性。采用多层叠加策略来定制垂直、侧向和扭转载荷下的力学响应。采用Tsai-Wu破坏准则，采用层状壳单元进行有限元分析，评估应力分布并识别潜在破坏区域。试验验证了数值预测的准确性，在代表性荷载条件下刚度偏差小于10%。结果表明，采用各向异性碳纤维复合材料层合板实现具有刚度调节能力的紧凑、高效、可靠的悬架系统是可行的。提出的方法提供了一种经过验证的设计方法，适用于长距离太阳能汽车竞赛，其中重量、安全性和部分损坏下的可操作性至关重要。

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来源期刊

Composite Structures 工程技术-材料科学：复合

CiteScore

12.00

自引率

12.70%

发文量

1246

审稿时长

78 days

期刊介绍： The past few decades have seen outstanding advances in the use of composite materials in structural applications. There can be little doubt that, within engineering circles, composites have revolutionised traditional design concepts and made possible an unparalleled range of new and exciting possibilities as viable materials for construction. Composite Structures, an International Journal, disseminates knowledge between users, manufacturers, designers and researchers involved in structures or structural components manufactured using composite materials. The journal publishes papers which contribute to knowledge in the use of composite materials in engineering structures. Papers deal with design, research and development studies, experimental investigations, theoretical analysis and fabrication techniques relevant to the application of composites in load-bearing components for assemblies, ranging from individual components such as plates and shells to complete composite structures.