The document describes simulations of a vehicle with an innovative collapsible and contractive anti-roll bar design. The simulations show that, compared to a standard vehicle, the new design provides: improved handling performance with up to 2.5% higher lateral acceleration; enhanced ride comfort with up to 18% lower vertical acceleration; and better agility with the vehicle's center of mass lowered by up to 4.8%.
1. Collapsible and Contractive antiroll bar
Automotive application
Inventor: Mr Fausto Garsi
November 2013
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2. Bushidō Consulting - Overview
Bushidō Consulting is a business development consulting firm and a professional network,
with operational offices in Turin, Modena, and Rome - Italy, Baden Baden - Germany,
Prague - Czech Republic and Detroit - USA.
Established in May 2010, capitalizing on 20 years of international experiences in the
automotive business by its founder Maurizio Agostini and professional Partners across the
whole product lifecycle: Marketing, Business Development, Product and Process
Engineering, Quality Management, Manufacturing, Key Account and Retail Sales, Dealer
Network Development, Product Support.
The Partners acquired such experience and competence working in management positions
within international world-class corporations such as:
Specialized in supporting enterprises of all sizes to create sustainable growth through
successful expansion into international markets.
Helping clients become more competitive and profitable in their business, providing sales
and marketing development expertise and executive PwC use only
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3. Mr Fausto Garsi - Profile
Born in Milan - Italy on September 27th, 1969
Graduated in Mechanical Engineering from the Politecnico of Milan
Involved since 2002 in the racing car field as race car engineer
Currently Technical Director of a Formula 3 Team
Resident in Milan - Italy
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4. Project of cooperation
Bushidō Consulting and Mr Fausto Garsi have an agreement for the development of a project
of cooperation.
Mr Fausto Garsi has decided to avail itself of the service offered by Bushidō Consulting, which
foresees a business development support concerning the presentation of an innovative
automotive mechanical device concept by key cars manufacturers and Tier1 suppliers in
Europe, other reference countries can be considered.
The device concept is covered by a relevant Patent and is related to the configuration of a
collapsible and contractive anti roll bar for vehicle applications.
The aim of the project of cooperation is to identify opportunities of design application within the
automotive market, through the definition and execution of a relevant project development plan.
Bushidō Consulting is responsible for the development of initiatives involving car manufacturers
and OEMs interested in the above mentioned device concept and acts as main point of contact
with them.
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5. Collapsible and Contractive antiroll bar
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6. Patent - Description
COLLAPSIBLE AND CONTRACTIVE ANTI ROLL BAR FOR VEHICLE APPLICATIONS
Deposit number: MI2011A002097 -
Italian patent extendable abroad with validly claiming priority
Inventor: Mr Fausto Garsi - Resident in Milan (Italy) Via Donna Prassede 3
Date of Deposit: November 11th, 2011
A mechanical device is applied inside the link rods and in the middle of the roll bar itself,
two relevant functions are provided as described here below:
Collapsibility: when the vehicle gets a significant bump from the road, the device collapses,
suddenly reducing the anti roll bar stiffness.
Contractiveness: a less stiff anti roll bar behaviour on the compressed side, while
maintaining the same roll bar overall characteristics in terms of stiffness. The roll centre
gets lower in turns.
Chance to have an anti roll bar with two different stiffnesses, which makes it possible to
improve the car handling performance and to increase the comfort behaviour at the same
time.
Device easily produced, low cost application.
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7. Device design details 1/3
Sketch
Joined to the vehicle chassis
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8. Device design details 2/3
Link-rod device part assembly description
Device made with 3 different springs K1 – K2 – K3
K1 preloaded works for collapsibility
K3
K2 is softer than K3 and works on the compressed side
K3 works on the side in extension (inner side in turn)
K2
K1
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9. Device design details 3/3
Roll bar device part assembly description
The bar works as a traditional one in case of on phase forces
The centre of the bar gets locked to the chassis in case of opposite forces
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10. Link Rod device part purpose - Collapsibility function
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11. Link Rod device part purpose - Contractiveness function
CG = Centre of Gravity
Kroll = Roll Stiffness
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12. Different roll bar stiffness to equal roll angle
The contractive effect gets the Mass Centre Lower on turn, then assuming the same lateral
acceleration, the roll moment gets less because multiplied by a shorter arm due a lower Centre
of Gravity Height (CGH)
Lat G = Lateral Acceleration
CGH = Centre of Gravity Heigh
RM = Rolling Moment = Lat G * CGH
STANDARD
CONTRACTIVE
RM 1
Lat G 1
RM 2
Lat G 2
CGH 1
CGH 2
Lat G 1 = Lat G 2
CGH1 > CGH 2
RM 1 = Lat G 1 * CGH 1 > RM 2 = Lat G 2 * CGH 2
Considering a less Rolling Moment it is possible to have the same roll angle with a softer roll bar
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stiffness.
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13. Collapsibility working sketch
K1 gets compressed when the force goes over the
preload.
Preload settled equal to max Force in roll stress.
K1 compressed
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14. Contractiveness working sketch
Outer corner side
Inner corner side
K3 compressed
K2 compressed
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15. Roll Bar device purpose
Undeformed bar
Deformed bar
No contractive effect because
the bar turns
Central device locks the bar to
the chassis allowing the
contractive effect
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16. Track test and related data
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17. Track test - Reference Data 1/2
Comparison between two Formula 3 cars (Imola circuit - Italy, chicane passing through) with
and without the device installed.
Data trace, see also next page:
collapsible/contractive
- BLACK – car with collapsible/contractive device
- RED – standard car without device
Trace 1 – Car speed [kph]
Trace 2 – Steering Wheel angle [°]
Trace 3 – Throttle [%] / Brakes Pressure [bar]
Trace 4 – Engine revs [rpm] / Number of gear engaged
Trace 5 – Time difference [s]
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18. Track test - Reference Data 2/2
collapsible/contractive
collapsible/contractive
speed
standard
steering wheel angle
Throttle
Brakes press
rpm
gear
Time difference
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19. Collapsible and Contractive antiroll bar
New and alternative design
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20. New and alternative roll bar design
The contractive effect can be realized by a new and alternative roll bar design:
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21. New and alternative roll bar design
Two coaxial pipes connected to give different stiffness at each side.
Solution applicable in case the available link rod dimensions are not enough to install 3 springs.
Possibility to get a higher stiffness range than in the case of springs application.
Possibility to get a proper pre load on the anti roll bar.
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22. Preload system applied to the alternative Roll Bar
On the new and alternative Roll Bar it is possible to apply a proper preload.
The preload gives the possibility to optimize stiffness characteristics within the Roll bar range work.
Very useful on finding a fine tuning during the vehicle final set up.
The preload system design is available.
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23. Preload and decreasing rate characteristics
Possibility to have improved roll bar stiffness characteristics
Better vehicle handling and ride comfort are respectively the consequences of an
initial infinite stiffness and a softer rate over a settled level of roll force
F
Standard Bar
Collapsible effect
Max Force in Roll
Roll Bar Preload
Infinite Stiffness
Deflection
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24. Simulations
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25. Simulations Models - Stiffness Parameters
Simulations performed, comparison between a Reference Std Vehicle and Vehicles with the following
characteristics:
Equivalent Roll Stiffness : total roll bar stiffness equal to the reference vehicle.
Equivalent Roll Angle : total roll bar stiffness in order to get an equivalent roll angle to the reference
vehicle.
Front Antiroll Bar
[Nmm/°]
Front Spring
Reference Std Equivalent roll
Vehicle
Stiffness
3350
20100
[N/mm]
57.23
/
22
4
/
900
250
[N/mm]
Front Drop Link Spring
57.23
[N]
Front Pre Load
57.23
[N/mm]
Front Pre Loaded Spring
Rear Antiroll Bar
Equivalent
Roll Angle
10050
/
22
4
1800
10800
5400
[Nmm/°]
Rear Spring
[N/mm]
108.28
108.28
108.28
Rear Pre Loaded Spring
Rear Pre Load
[N/mm]
[N]
/
12.5
2.27
/
450
150
Rear Drop Link Spring
[N/mm]
/
12.5
2.27
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26. Multi Body Vehicle Model Characteristics
Total Mass
1617 [kg]
Front Track
1.658 [m]
Rear Track
1.600 [m]
Wheelbase
2.600 [m]
COG Height
0.470 [m]
Tyres Model :
Magic Formulae Tyres
Front Tyres
225/35 R19
Rear Tyres
285/35 R19
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27. Simulations - Results
For the relevant specifications see the next page.
Reference Std
Vehicle
Equivalent roll
Stiffness
Equivalent Roll
Angle
Max Roll Angle [°]
3.55
2.91
3.55
Max Lateral Acceleration [g]
1.029
1.056 / +2.62 %
1.055 / +2.53 %
COG Height in Turn [mm]
479.8
456.6 / -4.83 %
456.4 / -4.87 %
Ramp Steer Simulation
Pitch Variation in turn
Front / Rear [mm]
Total Variation ∆ nose up / down [mm]
F +3.5 / R -3.8 F -27.0 / R -19.1 F -28.7 / R -17.7
∆ 7.3 up
∆ 7.9 down
∆ 11.0 down
Steering Pad Simulation
Max Roll Angle [°]
3.51
3.41
3.51
Max Lateral Acceleration [g]
1.0026
1.0033 / +0.07 % 1.0028 / +0.02 %
Comfort Road
RMS Vertical Acceleration [m/s^2]
0.247
0.1983 / -19.7 % 0.2025 / -18.0 %
0.1751
0.1643 / -6.17 % 0.1610 / -8.05 %
Bump Ride in Turn
Max Vertical Acceleration [g]
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28. Simulations - specifications
Ramp Steer
The vehicle at constant speed of 100 kph turns the steering wheel from 0° up to 120° in19 seconds
time.
Steering Pad Constant Radius
The vehicle, after a short straight, follows a 100 metres radius curve line, increasing the speed from
70 kph to 150 kph in 30 seconds.
Comfort Road
The vehicle at 70 kph constant speed rides an extra urban road profile. The road profile is in opposite
phase between the 2 car sides.
Bump Ride in Turn
The vehicle at 100 kph on turn rides a plateau profile bump only on the inner turn wheels.
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29. Summary
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30. Simulations results - Summary
Better Handling Performance: + 2,5 % Lateral Acceleration
Better Ride Comfort: - 18.0 % Vertical Acceleration
Better Agility Behaviour: - 4.8 % Centre Mass Height
Better Ride comfort on high bump : - 8.05 % Vertical Acceleration
Positive Pitch angle on turn: 11 mm (nose down) equal to more aero down force.
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31. Device characteristics - Summary
Better general car handling because of the lower Centre of Gravity in Turns combined with
better comfort.
Roll bar characteristics with different stiffnesses in the work range, getting the possibility to
find a better vehicle set up with different behaviours combined.
Possibility to increase the car pitch angle on turn, extremely important benefits especially
for down force vehicles.
Application suitable for all kinds of vehicles, NOT only for sport cars, even better for
vehicles such as the SUV, because of the weight , high Mass centre and big roll angle.
Fully mechanical device.
Low cost and extremely reliable.
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