What really matters!

Transcription

1 What really matters!

2 2 3 Content BILSTEIN

3 Contents Suspension technology 4 11 Technology transfer from original equipment manufacturing and motor sports Gas pressure shock absorbers Twin-tube vs. mono-tube technology BILSTEIN upside-down technology Adjustment systems Height adjustment at BILSTEIN level Road test The product range as a whole 56 71

4 4 5 Suspension technology BILSTEIN

5 Chapter 1 Suspension technology

6 Motivation From motor sports and original equipment manufacturing to tuning and universal spare parts BILSTEIN is synonymous with top quality and high performance in suspension engineering. At BILSTEIN, customer requirements and our dedication to motor sports drive development and innovation. 6 7 Suspension technology BILSTEIN

7 Suspension technology What does it mean? Motor sport technology for everyday roads It s not just engine power and driving ability but also a vehicle s driving dynamics that are vital to success in motor sports. A crucial role is played by the heart of the suspensi- oversteer and understeer. In motor sports, extremely high speeds together with bumpy tracks, radical curb riding and rapid load changes subject shock absorbers to extreme stresses and strains. But drivers who want to experience sporty driving with their own vehicles also have to be able to depend on the right components. Whether in an everyday situation or on the Nürburgring s technology quickly becomes clear. Road grip traction comfort As the link between the road and the car body, the suspension s task is to reduce the vibrations from the wheels ( unsprung masses) and the car body in as controlled a manner as possible. Every attempt must be made to prevent these vibrations from being transmitted to the car body in order to reduce rocking and pitching, prevent swaying and ensure optimum road contact and traction with minimum slip. If a vehicle s suspension travel on an uneven surface were reduced to zero, it wouldn t be possible to drive the vehicle. The result would be a great loss of both traction and comfort.

8 Damped Undamped Vibration absorption The vibration absorber is an energy converter that transforms kinetic energy into thermal ned valve passages in the shock absorber piston slow the piston rod down as the oil Basic function shock absorber The task of the shock absorber, or more precisely the vibration absorber, is to reduce the vertical vibrations of the car body and the wheels. It doesn t perform any directional control tasks. With most vehicles, this component is attached to the rear axle. 8 9 Suspension technology BILSTEIN

9 Transverse forces Longitudinal forces Basic function strut Lightweight construction is of great importance in automotive design. As a result, the McPherson strut was developed. While a shock absorber is only subject to tensile and compressive forces when the vehicle is compressed or rebounds, the strut is subject to a much higher degree of stress. The strut helps control the wheels and is subjected to additional lateral and transverse forces when cornering, braking and accelerating.

10 75 % 25 % Interaction between the spring and the shock absorber When traversing an obstacle, the initial forces impact on the spring. Its function must not be impaired by a high degree of shock absorbtion. Once the spring has compensated for the obstacle, the shock absorber must slow the motion of the forcefully released spring. To do this, it provides compression and rebound forces in a ratio of approx. 25 % : 75 %. Lowering and sport suspensions pure driving pleasure! Drivers who lower their vehicles want dynamic vehicle handling, along with a unique, sporty look and perfect road holding. Achieving these ring amount and the use of high performance technology so as to deliberately reduce suspension travel and change the vehicle dynamics and axis geometry. When reducing the suspension travel, the spring and shock absorber forces must be completely redesigned. As this kind of suspension is subject to higher loads, high performance components are essential. Complete suspensions by BILSTEIN are the ideal solution for pure driving pleasure! Suspension technology BILSTEIN

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12 12 13 Technology transfer BILSTEIN

13 Chapter 2 Technology transfer from original equipment manufacturing and motor sports

14 14 15 Technology transfer BILSTEIN

15 Technology transfer from original equipment manufacturing and motor sports The goal To take all of the insights gained from original equipment manufacturing for companies such as BMW, Mercedes-Benz, Aston Martin, Land Rover, Nissan, Bugatti and Porsche as well as from the extensive involvement in endurance racing at the Nürburgring, the Baja races in California and Formula 3 racing, and transfer them 1 : 1 into the BILSTEIN product range. The requirement Motor sport teams need for a suspension that could be optimally adapted to race tracks with widely varying demands led to BILSTEIN developing threaded ride high adjustable kits almost 40 years ago. The requirements were clear: stress-free, perfect driving performance in every situation, uncompromising handling, solid shock absorption right from the start and a high degree of reliability. Uncompromising solutions The technology developed and continually enhanced by BIL- STEIN engineers precisely met these requirements. From gas pressure, mono-tube and upside-down technology to parallel shock absorption adjustment: the right technologies are used in the right situations to yield the ideal product.

16 16 17 Gas pressure shock absorbers BILSTEIN

17 Chapter 3 Gas pressure shock absorbers

18 Gas pressure shock absorbers Basic principle The oil column of the mono-tube gas pressure shock absorber is constantly pressurised by an additional gas volume separated by a dividing piston. Pressure differences All shock absorber oil contains about 10 % gaseous air in a molecular bound state. The movements of the shock absorber piston within the oil column cause pressure When the piston rod is thrust abruptly into the shock absorber interior due to an uneven road surface, pressure rises in front of the piston and falls behind the piston. Oil Gas Overpressure Gas pressure shock absorbers BILSTEIN

19 Gas pressure shock absorber, no foaming Non-pressurised shock absorber, foaming Loss in performance bubbles form (foaming). On longer drives the foaming in the shock absorber oil can be so great that the suspension force is considerably reduced sometimes by as much as up to 35 %. The shock absorber no longer provides good shock absorption. The wheels lose road grip; traction and driving dynamics are majorly impaired. Performance pressure The nitrogen gas in a gas pressure shock absorber, which is separated from the oil by a dividing piston, keeps the oil column pressurised, thus preventing the release of the shock absorber oil s gas molecules (foaming). The bottom line: Only gas pressure shock absorbers offer drivers constant shock absorption in every driving situation. How can you recognise a gas pressure shock absorber? The piston rod extends of its own accord when the shock absorber is disassembled.

20 20 21 Twin-tube technology vs. mono-tube technology BILSTEIN

21 Chapter 4 Twin-tube technology vs. monotube technology

22 22 23 Twin-tube technology vs. mono-tube technology BILSTEIN

23 Twin-tube technology vs. mono-tube technology The challenge When kinetic energy is converted into thermal energy, temperatures of up to 150 C can be generated while driving. This thermal energy must be dissipated to prevent a loss of performance and possible failure.

24 Twin-tube technology More than 90 % of all series production vehicles are equipped with twin-tube shock absorbers. When using this double-walled shock absorption system, the thermal energy generated cannot be directly dissipated into the environment. The working piston located in the inner shock absorber tube can assume the diameter of the inner shock absorber tube as a maximum. The small working piston diameter and the resultant of great pressures that in turn cause increased wear. Oil 150 o C Twin-tube technology at a glance: Two tubes Greater wear High thermal load Loss of performance Foaming Loss of performance Short service life Installation position only up to max. 45 Greater tolerances Low overall length at the same stroke in comparison with mono-tube outer tube Inner wall has no functional surface Twin-tube technology vs. mono-tube technology BILSTEIN

25 Mono-tube technology standard in motor sports as well as in luxury sports cars. The perfect drive performance of these systems speaks for itself. Mono-tube shock absorbers are only available as gas pressure shock absorbers. With this single-walled shock absorption system, the thermal energy generated in the shock absorber is directly dissipated into generated by the large working piston. At the same time, high suspension forces are available, ensuring constant, high shock absorption. The gas pressure prevents the oil from foaming. The sion engineers are always available and ensure perfect, dynamic drive performance. Oil Gas 150 o C Mono-tube technology at a glance: One tube Direct heat dissipation No overheating Required suspension power always available Installation independent of position Upside-down design possible with suspension struts Large working piston Greater production accuracy Higher costs

26 ratios: General formula for calculating the effective piston surface A W A w = d d 22 4 A w d 1 Ø working piston Ø piston rod d 2 Competitor, front axle (twin-tube) A = (33,07) 2 4 (21,98) 2 4 = 858,94 mm 2 379,44 mm 2 = 479,49 mm 2 effective piston surface Calculation of the pressure (with constant force) P = F A = N N = 4,171 = 41,71 bar 479,49 mm 2 mm Twin-tube technology vs. mono-tube technology BILSTEIN

27 BILSTEIN front axle (mono-tube) A = (35,56) 2 4 (13,98) 2 4 = 993,15 mm 2 153,50 mm 2 = 839,65 mm 2 effective piston surface Calculation of the pressure (with constant force) P = F A = N = 2, ,65 mm 2 N mm 2 = 23,82 bar The bottom line: Better handling, greater comfort, high safety reserves. BILSTEIN mono-tube shock absorbers can be perfectly tuned to every type of load. With BILSTEIN mono-tube technology, the larger effective surface decreases the pressure in the shock absorber by nearly half, considerably reducing wear and the risk of leaks and ensuring long-term reliability.

28 Overview of the advantages* A BILSTEIN technology comparison Mono-tube Twin-tube System type Mono-tube Twin-tube Pressurisation Gas pressure Gas pressure Effective surface of the working piston, front axle 845,24 mm 2 479,49 mm 2 Effective surface of the working piston, rear axle 1504,79 mm 2 597,2 mm 2 The bottom line durability. The lower working pressures reduce wear and improve setting characteristics. Chrome layer piston rod hardness, front axle HRC HRC Chrome layer piston rod hardness, rear axle HRC HRC Piston rod surface roughness, front axle 0,29 μm 0,32 μm Piston rod surface roughness, rear axle 0,28 μm 0,32 μm Piston rod chrome thickness, front axle 34,2 36,2 μm 27,1 32,5 μm Piston rod chrome layer thickness, rear axle 33,4 35,8 μm 27,8 31,6 μm The bottom line The higher quality of the materials used and the outstanding workmanship ensure extreme reliability when using our products Twin-tube technology vs. mono-tube technology BILSTEIN

29 Mono-tube Twin-tube Material type Precision steel tube Normal stainless steel The bottom line The use of precision steel instead of normal stainless steel preserves the basic elasticity of the shock absorber tube, preventing the risk of oil loss and shock absorber failure. Adjustment type Simultaneous compression and Rebound separate from rebound compression Adjustment range 10 clicks for better/ Up to 18 clicks (rebound) greater kingpin inclination Up to 12 clicks (compression) Adjustment handling One rotation Three rotations Rebound stage setting problematic Compression and rebound because there is only one adjuster adjuster on each shock absorber for all of the shock absorbers Assessment Adjustment range recorded Fixed measurement recorded The bottom line In contrast to the competition, you always achieve the right adjustment when handling the BILSTEIN shock absorber. With three rotations, click division is not useful. requirements more easily and precisely. * Based on an example of a threaded ride high adjustable kit with suspension force adjustment.

30 30 31 upside-down technology BILSTEIN

31 Chapter 5 BILSTEIN upsidedown technology

32 BILSTEINupside-down technology Suspension struts Suspension struts are shock absorption systems that simultaneously guide the wheel and absorb vibrations. Upside-down technology High-performance struts are built into mono-tube technology. Known as BILSTEIN upside down technology, this was developed for motor sports where it now dominates. The lower end of the piston rod is attached into the tube body. The wear-resistant chrome tube moves up and down on slide bearings distributing the restoring and lateral Noticeable difference The high transverse forces that also occur during high performance This in turn reduces driving safety and performance. With its special design, the BILSTEIN upside-down suspension strut provides series safety and comfort. On installing this system, the improvements in driving stability are instantly perceptible. Moreover, the drive performance is improved through the non-use of stainless steel to produce the stand tube and the use of a large chrome tube upside-down technology BILSTEIN

33 BILSTEIN upside-down suspension strut The large chrome tube can absorb extreme transverse forces The mono-tube technology ensures direct dissipation of thermal energy Due to the large outer diameter of the chrome tube, little selective friction occurs Careful material selection (no stainless steel) guarantees controlled, dynamic responses during both compression and rebound The large working piston ensures maximum suspension force, optimum setting and low thermal loads The piston rod is not subject to any transverse forces The shock absorption system is protectively located inside the suspension strut

34 The bottom line: Thanks to its technological features, BILSTEIN upside-down technology ensures highly dynamic yet comfortable vehicle handling. The vehicle feels extremely compact and can be easily controlled in any driving situation upside-down technology BILSTEIN

35 Comparison mono-tube vs. twin-tube How can I recognise upside-down technology? The chrome tube is clearly visible at the top of the suspension strut.

36 36 37 Adjustment systems BILSTEIN

37 Chapter 6 Adjustment systems

38 Manual adjustment systems Compression and rebound stage with a single turn In creating the shock absorbers in the BILSTEIN B16 series, BILSTEIN engineers have established a new performance class. 9/10 charac- absorbers s performance in the rebound and compression stage as exact and parallel. When installed, these stored settings can be precisely selected with a single turn of the aluminium wheel a clear click indicates the correct setting. There are ten clicks in one rotation of the setting wheel Adjustment systems BILSTEIN

39 Correct setting is assured Depending on the wheel/tyre combination ( unsprung masses) or driving situation, drivers can adjust the BILSTEIN B16 setup to meet their individual needs. The compression and rebound stages of the BILSTEIN B16 always correspond perfectly with each other for pure driving pleasure. The simultaneous suspension force adjustment (simultaneous adjustment of the compression and rebound stages) is only possible with high quality mono-tube systems. Characteristic curve diagram, BILSTEIN B16 Rebound Suspension force [N] Compression stage Rebound stage Speed [mm/s] Stage 1 Stage 3 Stage 5 Stage 7 Stage 9 Stage 2 Stage 4 Stage 6 Stage 8 Stage 10

40 Manual adjustment systems Separate compression and rebound forces Your customised setting Our premium quality BILSTEIN Clubsport threaded ride high adjustable kits meet the highest of the high demands in motor misable. Compression and rebound forces can be set separately using highly visible setting wheels with clear scales. Quick, precise and professional Changing the setup here is as easy as pie with 10 x 10 clearly perceptible clicks. This enables drivers to create their own characteristic curve combinations between soft (1) and hard (10). Perfect control Using the camber adjustment, these characteristic variations, together with the supplied uniball supporting bearings, make it possible to select the optimum setup for the road surface, weather conditions, vehicle weight, tyre and aerodynamic parameters and driver characteristics Adjustment systems BILSTEIN

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42 Electronic adjustment systems BILSTEIN B16 ridecontrol In full control If you don t want to make any compromises on the road, you have to have everything under control. Ideally, this means in your vehicle cockpit. BILSTEIN ridecontrol provides an exclusive setting system at the touch of a button. You can switch from comfortable to sporty driving quickly and conveniently from inside your vehicle.innen steuerbar. The bottom line: The perfect setting depends on the ability to individually adjust the most important parameters. BILSTEIN provides key technologies from the world of motor sport for everyday driving pleasure Adjustment systems BILSTEIN

43 BILSTEIN B16 DampTronic Uncompromising dynamics We provide an exclusive power class for owners of BMWs, special qualities of an active suspension through the use of the BILSTEIN B16 DampTronic. This is perfectly adapted to the series-production electronic adjustment system while also drivers enjoy improved road grip and greater tracking stability for comfortable everyday driving and extreme sport situations. The already outstanding driving dynamics are even further enhanced through the retention of the EDC and PASM.. The bottom line: At the touch of a button you can adapt your exclusive, active suspension to your individual needs and further improve the drive performance.

44 BILSTEIN B16 irc Active adjustment with that certain touch The well-known BILSTEIN ridecontrol system for suspension control has been further enhanced with a convenient feature: control by iphone app. Instead of the familiar button (switch), an iphone can now be used to set the system with irc. Drivers can switch between the basic modes comfort+ and sport+. With famous BILSTEIN precision, the comfort+ mode smoothly compensates for bumpy road surfaces while the sport+ mode ensures excellent driving dynamics and optimum power reserves when driving at the limit Adjustment systems BILSTEIN

45 Finest measuring technology for perfect switching The auto mode selects a suspension setting depending on the driving conditions that the highly sensitive sensor technology reports to the control unit. The sensor sensitivity can be acceleration thresholds and, above all, the control intervals. programming results on the iphone screen makes manually conducting settings easy.

46 46 47 Height adjustment at BILSTEIN level BILSTEIN

47 Chapter 7 Height adjustment at BILSTEIN level

48 Height adjustment at BILSTEIN level Lowering at the highest level Lowering is a question of character with respect to both the vehicle and the driver. Based on extensive testing experiences, our test The wedge-shaped suspension Lowering of approx. 60 mm at the front axle and approx. 40 mm at the rear axle creates a highly sporty appearance that packs a huge visual punch. Uniform lowering Lowering the entire vehicle by approx. 30 mm emphasises the driving dynamics without compromising on comfort or suspension travel. The BILSTEIN threaded ride high adjustable kit This version of lowering allows smooth and variable tuning in line with your desired balance between sporty characteristics and comfort Height adjustment at BILSTEIN level BILSTEIN

49 The wedge-shaped suspension 40 mm 60 mm Uniform lowering 30 mm 30 mm The BILSTEIN threaded ride high adjustable kit mm mm

50 The right level Threaded height adjustment makes it possible to adapt the car body height and vehicle balance to drivers needs. Level corrections of up to 20 mm with our threaded ride high adjustable kits have already been TÜV registered. The perfectly designed combination of shock absorbers and springs guarantees ideal spring pre-tension with optimum suspension travel over the entire adjustment range. The spring plates and lock nuts are made from aluminium. The threaded tubes protective coating exceeds the applicable DIN standards and the requirements of the automotive industry and ensures durable adjustability. Air suspension Perfect support for the functionality of the vehicle manufacturer s active suspension systems. The bottom line: Both in motor sports and on the roads the right combination of applied technology and optimum material selection, vehicle height, spring rate and shock absorber setting is crucial for your driving pleasure and success. BILSTEIN offers perfection at the highest level Height adjustment at BILSTEIN level BILSTEIN

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52 52 53 Road test BILSTEIN

53 Chapter 8 Road test

54 Road test Perfection is a matter of settings suspension engineers use high-end technologies and high performance components to develop suspensions that provide pure driving pleasure Road test BILSTEIN

55 Road tests The typical BILSTEIN tuning is tested in extensive road tests. BILSTEIN suspensions are tuned and tested to the limit on the Mercedes-Benz test track in Papenburg and the legendary Nürburgring Nordschleife, the toughest race course in the world. Several test drivers put the sus- the optimum settings. As the test conditions always remain the same, the test results can be reliably compared. The test phase High speed, lane changes, comfort, handling, vehicle balance, traction: during the test phase, the suspension must meet demands in all of these areas. And only if all the high BILSTEIN requirements are met does the suspension come onto the market in series production. After all, it s when you re pushing it to the limit that a perfectly tuned suspension becomes critical to driving pleasure and safety. Bottom line: Technology, perfection and experience result in driving dynamics and safety. Hydropulser

56 56 57 The product range as a whole BILSTEIN

57 Chapter 9 The product range as a whole

58 The product range as a whole The perfect range of products for every need The product range as a whole BILSTEIN

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60 BILSTEIN B1 B4 Universal spare parts BILSTEIN technology for almost every type of vehicle. With sion components for every driver and every wallet size. Of course, the parts come in high OEM quality and incorporate BILSTEIN s years of experience The product range as a whole BILSTEIN

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62 BILSTEIN B6 B8 High-performance shock absorbers Drivers who have experienced our high-performance shock absorbers know how much untapped power is available from their vehicles. Whether meeting your demands for sporty handling or withstanding frequent driving under heavy loads, with these yellow BILSTEIN components your vehicle is certain to excel itself The product range as a whole BILSTEIN

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64 BILSTEIN B12 B16 Sport and threaded ride high adjustable kits With BILSTEIN sport and threaded ride high adjustable kits you will experience new dimensions in sporty driving. A unique appearance, a customised look and vehicle handling tailored to your own requirements enjoy every road, every curve and every inch of asphalt The product range as a whole BILSTEIN

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66 BILSTEIN B16 ridecontrol, DampTronic and irc Electronic suspensions a button. World class technology for anyone who refuses to compromise in life or on the road. Press the button to switch instantly from comfortable to sporty and back again. BILSTEIN B16 irc the BILSTEIN app for active suspension control The product range as a whole BILSTEIN

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68 BILSTEIN Clubsport Racing and road driving in one The BILSTEIN Clubsport suspension is the high-end, threaded and is also designed for uncompromising use in racing and club sports. The suspension combines the proven BILSTEIN mono-tube gas pressure technology with the highest technological requirements from the world of motor sports The product range as a whole BILSTEIN

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70 BILSTEIN motor sports Motor sport suspensions When used in racing vehicles, our BILSTEIN motor sport suspensions ensure maximum contact between the wheels and the race course. Many racing teams trust in the BILSTEIN MDS suspension with an adjustable compression and rebound stage and, in so doing, secure their podium positions The product range as a whole BILSTEIN

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72 Your suspension specialist: Find us on Facebook ThyssenKrupp Bilstein GmbH Milsper Straße 214, D Ennepetal Postfach 1151, D Ennepetal +49 (0) (0) W Subject to technical changes, misprints and errors.