Using fibre optical sensors for validation purposes in GFRP transverse leaf springs

Abstract

The integration of composite materials in vehicle structures offers potential for weight savings and improved fatigue strength. In a McPherson suspension, further weight reduction can be achieved by replacing the control arms, coil springs and anti-roll bar with a transverse leaf spring. However, the development of a glass fibre reinforced transverse leaf spring with an integrated wheel control function is challenging due to a large number of design and laminate parameters. The geometry of the tested leaf spring prototype was provided by a previous optimisation process. The tests generate a large amount of data in different formats due to the complex measurement technologies (optical sensor fibres, photogrammetry, strain gauges, load cells). The focus is on automated data processing of both the test data and the FE data, especially the optical sensor fibres, which are modelled in their original positions. The forces, strains and displacements (elastokinematics) of both disciplines are automatically compared visually using charts and a 3D user interface of the leaf spring model including sensor fibres.