Technology helps provide exceptional blend of on- and off-road performance
New materials and manufacturing processes meet challenging targets
LUTON, United Kingdom, Sept. 23 /PRNewswire/ -- Innovative air suspension
technology is helping Land Rover combine the legendary off-road ability of its
vehicles with exceptional refinement and driving dynamics. A key part in the
development of the airspring modules was played by Delphi Corp (NYSE: DPH),
which manufactures the units at its facility here. The new technology will be
available on the Discovery 3 (called LR3 in North America), launched at the
Mondial de l'Automobile show in Paris today.
(Logo: http://www.newscom.com/cgi-bin/prnh/20020315/DEF002LOGO )
"The Discovery has always had an outstanding reputation for off-road
ability, which had to be maintained with the new vehicle," said Guy Hachey,
Delphi vice president and president, Delphi Energy & Chassis. "The challenge
was to combine this with levels of suspension refinement that would normally
be expected in conventional luxury vehicles."
Land Rover also set tough targets for packaging, durability and the air
spring's ability to maintain vehicle trim height, even when left fully laden
for long periods with the engine off. The packaging requirement dictated the
use of small volume air springs, which made the refinement target more
challenging because the smaller air volume drives very high internal operating
pressures, introducing the possibility of suspension harshness.
The vehicle's ability to travel quickly on poor surfaces presented further
challenges because air springs have a natural tendency to become stiffer under
low amplitude / high frequency road inputs, again potentially leading to
suspension harshness.
The technology chosen uses front and rear airspring modules with integral
twin-tube gas dampers, controlling the vehicle's four-wheel independent
suspension. Delphi's engineers developed a new generation of compact, very
high-pressure airspring units and new manufacturing and testing techniques to
provide consistently high quality.
The new airspring modules allow Delphi to meet the packaging targets and,
compared with conventional coil springs, weigh about 7 kg less. The units are
designed to withstand the most demanding burst pressure and temperature range
requirements set by any vehicle manufacturer.
The new design of airsleeve is constructed of soft, thin rubber reinforced
with nylon chords: a construction chosen to minimize suspension harshness. An
aluminum restraining cylinder is placed around the airsleeve to give it
rigidity, increase durability and allow it to resist very high pressures.
Protection from mud and stones is provided by a rubber gaiter.
During the design processes, Delphi engineers paid particular attention to
component sharing between front and rear units and to design-for-manufacture,
allowing faster development and reducing both development and manufacturing
costs. Final calibrations were supported by Delphi's mobile 'ride
laboratory,' which allows the specification of components such as dampers, air
springs, spring aids, and top-mounts to be quickly changed and evaluated on
the vehicle.
Several new manufacturing and quality control processes were developed to
provide that the units will withstand the very high pressures required. More
than 35 in-line tests confirm critical stages of assembly, including two high-
resolution laser gauges accurate to just 0.001mm. At the end of the
production line, a custom helium leak test system is used to verify the
performance of every unit before delivery to Land Rover's plant in Solihull,
United Kingdom.
As well as enabling an outstanding combination of on- and off-road
ability, the air suspension system provides automatic self-leveling,
regardless of the mix of passengers, cargo or trailering requirements, the
ability to change the ride height for increased ground clearance or to improve
the approach and departure angles for off-road driving, and the ability to
lower the vehicle to ease loading or for trailer attachment.
Other Delphi technology on the Discovery 3 (LR3) includes Delphi's Smart
Cruise Control system to increase comfort on long journeys, an advanced airbag
system, a high-durability lead / calcium battery and a carbon canister for the
emissions control system.
For more information about Delphi, visit the Virtual Press Room is at
http://www.delphi.com/media .
SOURCE Delphi Corporation
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Related links:
http://www.delphi.com/media
Photo Notes:
NewsCom:
http://www.newscom.com/cgi-bin/prnh/20020315/DEF002LOGO
PRN Photo Desk, photodesk@prnewswire.com
Company News On-Call:
http://www.prnewswire.com/comp/076666.html
CONTACT:
Sara Brogan of Delphi Corporation,
+1-248-813-2481
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