Lesson 1Roll stiffness, anti-roll bar sizing and tuning to balance body control and ride comfortThis section explains roll stiffness distribution, anti-roll bar sizing, and bushing selection, showing how they influence body roll, understeer and oversteer balance, transient response, and the compromise between flat cornering and ride comfort.
Front vs rear roll stiffness splitAnti-roll bar diameter and materialLever arms, motion ratio, and rateBushings, links, and complianceUndersteer, oversteer, and comfortLesson 2Suspension layout choices for compact SUVs: MacPherson strut, double wishbone, multi-link — descriptions and comparative performance for ride and handlingThis section reviews MacPherson strut, double wishbone, and multi-link layouts for compact SUVs, comparing kinematics, packaging, cost, and their influence on ride comfort, steering feel, grip, and robustness on poor road surfaces.
MacPherson strut geometry and prosDouble wishbone camber controlMulti-link design and adjustabilityPackaging, weight, and crash loadsRide, handling, and tire wear impactLesson 3Structural considerations: chassis stiffness targets, subframe design for powertrain and suspension mounting, and NVH isolation techniquesThis section defines chassis stiffness targets, explains load paths and subframe design for powertrain and suspension mounting, and details NVH isolation strategies using bushings, mounts, and structural tuning to control noise and vibration.
Global bending and torsional stiffnessFront and rear subframe architecturesPowertrain mount layout and tuningBushing stiffness and isolation tuningBody panels, sealants, and dampingLesson 4Tire selection effects on handling, ride, and NVH: typical tire sizes, aspect ratios, and load ratings for compact hybrid SUVsThis section examines how tire size, aspect ratio, construction, and load rating affect handling, ride comfort, rolling resistance, and NVH, with guidance on selecting suitable tires for compact hybrid SUVs and validating them in testing.
Tire size and aspect ratio choicesLoad index and speed rating needsTread pattern, compound, and gripRolling resistance vs efficiencyTire NVH, roar, and road harshnessLesson 5Damping and spring tuning fundamentals: spring rates, damping ratios, ride frequency targets, and their effect on comfort over speed bumps and rough roadsThis section introduces spring rate selection, damping ratios, and target ride frequencies, then links these parameters to body control, wheel control, and comfort over speed bumps, potholes, and rough roads typical for compact SUVs.
Ride frequency targets front and rearChoosing primary spring ratesDamper curves and damping ratiosJounce, rebound, and bump stopsTuning for speed bumps and potholesLesson 6Rear suspension alternatives (torsion beam, torsion beam with Watts linkage, multi-link): trade-offs in cost, packaging, and handlingThis section compares torsion beam, torsion beam with Watts linkage, and rear multi-link suspensions, focusing on cost, weight, packaging, roll steer behavior, and how each option affects handling balance, ride comfort, and cargo space.
Basic torsion beam kinematicsWatts linkage geometry and effectCompact rear multi-link layoutsCost, mass, and manufacturing impactHandling, stability, and NVH traitsLesson 7Brake system concepts: disc vs drum, single vs dual-circuit hydraulics, brake booster options, and considerations for regenerative braking integrationThis section compares disc and drum brakes, single and dual-circuit hydraulics, and brake booster options, then explains how to integrate regenerative braking while maintaining stable pedal feel, fade resistance, and safety compliance.
Disc vs drum brake hardware and coolingSingle vs dual-circuit hydraulic layoutsVacuum, hydraulic, and electric boostersPedal feel, travel, and brake balancePackaging for hybrid and EV platformsLesson 8Regenerative braking strategy: blending algorithms, regenerative torque limits, ABS/ESC coordination, and energy recovery expectationsThis section details regenerative braking strategies, including torque blending with friction brakes, regen limits from tire grip and battery, ABS and ESC coordination, and realistic energy recovery expectations for urban and highway driving.
Regen torque maps and limitsBlending friction and regen torqueABS, ESC, and stability constraintsBattery SOC and temperature effectsEnergy recovery in real drive cyclesLesson 9Steering systems: electric power steering (EPS) architectures, assist level selection, steering ratio impact on low-speed maneuverability and highway stabilityThis section covers electric power steering architectures, assist level calibration, and steering ratio choices, explaining their impact on low-speed maneuverability, highway stability, steering feel, energy use, and integration with ADAS features.
Column vs rack EPS architecturesAssist curves and boost tuningSteering ratio and on-center feelReturnability and friction managementADAS integration and fail-safe modes
