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Abstract

Passenger car suspension and wheel angles have a strong influence on ride, handling, and tire wear. These angles are affected by both static vehicle alignment (as done at a wheel alignment shop) and by changes due to vehicle loading while driving. This thesis work evaluates the variability of wheel alignment angles under different load conditions with a large (~500) set of measurements. In addition, this data is compared to Kinematics and Compliance test data as done on a professional K&C machine.To get accurate variability information, large numbers of measurements are required and for these studies, nearly 500 were needed. However, wheel alignment measurements take a considerable amount of time so a study in which large numbers of measurements are needed, starts with a method for streamlining the measurement activities. The approach taken includes the construction of a rig to quickly and reliably raise a vehicle off the ground and place it safely on bearing plates. The system used allowed almost 500 complete wheel alignment measurements including caster sweeps. Unfortunately, the intense workload also wore out the pulley bearings on the modified four post lift and the lift nearly collapsed at around 490 measurements. Fortunately, the lift did not completely collapse and drop the Porsche 911 test vehicle to the ground. It did; however, require a large forklift to raise the car high enough to extract it from the lift.In addition, a full barrage of Kinematics and Compliance (K&C) test data was gathered at a professional K&C machine at the business, "Morse Measurements", in Salisbury NC. Comparisons between the experimental measurements and K&C values of camber, caster, toe, cross-camber, total toe and thrust angle were then made at various load conditions. These revealed a good comparison between the K&C machine and average of experimental values measured statically under varying loads. That is, the various trends in camber and toe as a function of load or suspension displacement (i.e. camber and toe curves) matched between the experiments and K&C test results.

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