The development of electrorheological fluids for an automotive semi-active suspension system

The feasibility of electrorheological (ER) dampers for an automotive semi-active suspension was evaluated in a three phase program. In the first phase, ER fluid performance targets were derived. The desired ride and handling attributes of the suspension system were translated into damper specifications, which were then translated into the ER fluid performance targets. The damper specifications included dynamic range, bandwidth, power draw, and packaging. The ER fluid performance parameters then included zero-field viscosity, ER stress, response time, and power density. In the second phase, the dampers and the ER fluid were developed to meet the performance targets. Trade-offs were made between damper design and fluid formulation to achieve the desired damper dynamic range and power draw. A state-diagram approach using screen test data was used to select candidate ER fluids. In the third phase of the program, a prototype semi-active suspension system using fast, continuously variable ER dampers was installed on a demonstration vehicle. Heave, pitch, and roll motions of the vehicle were controlled by applying voltages independently to the four dampers as determined by a modified sky-hook algorithm. The system was designed to respond in less than 10 ms with an average power requirement less than 40 W for normal road surfaces and handling. Laboratory data from a pressure driven flow screen test and a damper test are presented that document the ER fluid performance specification and selection process. Vehicle performance data are presented that demonstrate the features of ER technology for the semi-active suspension application. Remaining issues for commercialization of ER fluids are discussed.