Modelagem e fabricação parciais da suspensão frontal de um veículo leve híbrido (VLH)

Abstract

This final paper deals with the partial modeling and manufacturing of the front suspension of a Hybrid Light Vehicle (HLV) that has been developed at the Manufacturing Laboratory (LabMan) at the Federal University of Rio Grande do Norte (UFRN). The need for a robust and efficient front suspension system is highlighted, something that is often lacking in commercial trikes due to design and cost factors. Given the disadvantages related to the complexity and weight of conventional suspension systems (MacPherson and Double A) and the impossibility of acquiring commercial kits (due to the high import cost), the main objective of this work was the modeling and manufacturing of a suspension system based on a conventional trike design, using simplified reverse engineering techniques. The methodology employed consisted of an image-based reverse engineering approach based on a standard element, such as the diameter of a bicycle tire, to estimate the other dimensions through proportions and geometric relationships (parallelism, proportionality between pixels and triangulation), culminating in the construction of a geometric model in CAD software. A strategic modification to one of the parts in the assembly (called 'Part 1') was made to optimize the manufacturing process, resulting in simpler machining and significant time savings, even with a 12 mm loss in stroke. The results obtained confirmed the effectiveness of the image measurement, with the stroke of the modeled suspension presenting satisfactory results and close to the parameters provided by the manufacturer. The manufactured suspension proved to be structurally robust, articulating as expected and without locking, despite small gaps and misalignments observed. The rigidity of the assembly indicates that the loads of the steering system will be effectively transmitted, ensuring an immediate response. Finally, the final result obtained validated the applicability of the image-based reverse engineering technique for the reproduction of essential mechanical components such as the suspension, resulting in a functional, robust and adaptable system to the needs of the VLH project, with an agile and efficient manufacturing process. Future improvements, such as the machining of 'Part 1' to optimize the stroke, may be implemented as the project development progresses, with the final evaluation of its effectiveness subject to field testing on the complete vehicle.