By
Livano Yudistira 11112028
BACHELOR’S DEGREE in
MECHANICAL ENGINEERING – MECHATRONICS CONCENTRATION FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY
SWISS GERMAN UNIVERSITY EduTown BSD City Tangerang
15339 Indonesia
February 2017
Revision after the Thesis Defense on 26 January 2017
Livano Yudistira STATEMENT BY THE AUTHOR
I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
Livano Yudistira
____________________________________________
Student Date
Approved by:
Leonard Rusli, B. Sc., M. Sc., Ph. D.
____________________________________________
Thesis Advisor
Dr. Ir. Gembong Baskoro, M.Sc.
____________________________________________
Dean
Date
Date
Livano Yudistira ABSTRACT
DEVELOPMENT OF ELECTRICALLY ACTUATED HEIGHT ADJUSTABLE COILOVER SUSPENSION SYSTEM
By
Livano Yudistira
Leonard Rusli B. Sc., M. Sc., Ph. D., Advisor
SWISS GERMAN UNIVERSITY
Indonesia's infrastructure, especially in terms of roads are far from being perfect.
Uneven roads, potholes, and gravel are commonly scattered everywhere and are a potential cause for a potent and fatal accident to happen. These disturbances, may they even be small, can lead to many damages both major accident or even minor injury and damages to the vehicle. The purpose of this thesis is to propose an invention of an installment of an electrically actuated suspension that can either increase or decrease ride height of a vehicle from a remote-control that receive an input signal from the user or driver. The application of this installment may vary, from keeping a safe ground clearance of the vehicle to the increase of gravitational force required to do a high speed
Livano Yudistira cornering. The usage of a gear configuration, remote-control input (non-wireless), and electric DC motor will be included in this project. As of today, there is no other products available in the market that are similar to the project, although there are other products that upholds the same concept but with different actuation, such as the air suspension system.
Keywords: Automotive Suspension, Coilover Suspension, Infrastructure, Electrical Actuation System, Gear Configuration
Livano Yudistira
© Copyright 2017 by Livano Yudistira
All rights reserved
Livano Yudistira DEDICATION
To the prosperity of Indonesia Engineering To My Family
To Mi Amor
Livano Yudistira ACKNOWLEDGEMENTS
Thank you to Mr. Leonard Rusli for always supporting me through my thesis, although I know I am a tough one to deal with as a thesis student.
Thank you to Tjokro Group, Yeni Per, Sumber Bangsa Suspensi, and Dream Muffler for helping me in mechanical machining and design. Especially Mr. Ali from Dream Muffler as my personal fabricator and Mr. Andri from Tjokro Group for the advising on fabrication.
Thank you to all of my colleagues and friends for always supporting me and helping me through obstacles. Thank you to Swiss German University for facilitating me to do this thesis.
Thank you Venny Violetta Tiurindah, S.T., B.Eng. for always supporting me in my down times.
Livano Yudistira TABLE OF CONTENTS
Contents Page
STATEMENT BY THE AUTHOR ... 2
ABSTRACT ... 3
DEDICATION ... 6
ACKNOWLEDGEMENTS ... 7
TABLE OF CONTENTS ... 8
LIST OF FIGURES ... 11
LIST OF TABLES ... 14
CHAPTER 1 - INTRODUCTION ... 15
1.1.Background ... 15
1.2. Research Problem ... 16
1.3. Research Objectives ... 17
1.4. Significance of Study ... 17
1.5. Research Questions ... 18
1.6 Hypothesis... 19
CHAPTER 2 – LITERATURE REVIEW ... 20
2.1. Suspension System... 20
2.1.1. MacPherson Strut Suspension System ... 21
2.2. Coilover Suspension ... 21
2.3. Coilover Advantages against other Suspension System ... 22
2.4. Gears ... 23
2.4.1. Spur Gear ... 24
2.5. Electrical Actuation System ... 25
2.5.1. Electric DC Motor... 26
2.5.2 User-Input Device ... 27
2.6. Controllers and Microcontrollers ... 27
2.6.1. Arduino Micro-controller ... 28
2.7. Sensory System ... 29
Livano Yudistira
2.7.1. Limit Switch Sensor ... 30
CHAPTER 3 – RESEARCH METHODS ... 32
3.1. Introduction ... 32
3.1.1 System Concept Design ... 33
3.2. System Breakdown Structure ... 34
3.3. Initial Design ... 34
3.3.1. Initial Mechanical Design ... 35
3.3.1.1. Mechanical Design Revision 0 ... 35
3.3.1.2. Mechanical Design Revision 1 ... 36
3.4. Revisited Mechanical Design ... 39
3.4.1. Initial Prototype Mechanical Design ... 39
3.4.2. Gearing and Torque Translation Concept ... 40
3.4.3. First Prototype Final System Design ... 45
3.4.3.1 Lower Clamping Arm Design ... 53
3.4.3.2 First Prototype Overall Mechanical Design ... 56
3.4.4 Electrical and Sensory Design ... 58
3.4.5 First Prototype Completion ... 61
3.4.5. Failure Analysis and Revision ... 64
3.4.6. Revision and Second Prototype ... 69
3.5. Electrical Design Review ... 73
3.5.1. H-Bridge control module ... 76
3.5.2. Conclusion of the Electrical Design ... 80
CHAPTER 4 – RESULTS AND DISCUSSIONS... 81
4.1. Mechanical Product ... 81
4.2. Electrical Counterparts... 86
4.3. Testing and Failures ... 87
4.4.1. Extended Device ... 91
4.5. Errors and Conclusion Initial Testing ... 92
CHAPTER 5 – CONCLUSION AND RECOMMENDATION ... 93
Livano Yudistira
5.1. Conclusion ... 93
5.2. Recommendation ... 93
5.2.1. Sensory System ... 93
5.2.2. Retro-fitment to Vehicle ... 94
GLOSSARY ... 95
REFERENCES ... 96
APPENDIX A – MECHANICAL DESIGN... 97
A.1. SPUR GEAR RATIO 10... 98
A.2. SPUR GEAR RATIO 5... 99
A.3. SPUR GEAR SHAFT ... 100
A.4. TOP BRACKET MOUNTING ... 101
A.5. BOTTOM BRACKET MOUNTING (A) ... 102
A.6. BOTTOM BRACKET MOUNTING (B) ... 103
A.7 FULL DESIGN OF MECHANICAL COUNTERPARTS ... 104
APPENDIX B – ELECTRICAL CIRCUIT DIAGRAM... 105
B.1. ELECTRICAL DIAGRAM ... 106
APPENDIX C – CODING OF ARDUINO ... 107
C.1. CODING OF ARDUINO ... 108
CURRICULUM VITAE ... 110
