What really matters! - BILSTEIN · 28 | 29 Twin-tube technology vs. mono-tube technology BILSTEIN...
Transcript of What really matters! - BILSTEIN · 28 | 29 Twin-tube technology vs. mono-tube technology BILSTEIN...
What really matters!
2 | 3 Content BILSTEIN
Contents
1
2
3
4
5
6
7
8
9
Suspension technology 4–11
Technology transfer from original
equipment manufacturing and motor sports 12–15
Gas pressure shock absorbers 16–19
Twin-tube vs. mono-tube technology 20–29
BILSTEIN upside-down technology 30–35
Adjustment systems 36–45
Height adjustment at BILSTEIN level 46–51
Road test 52–55
The product range as a whole 56–71
4 | 5 Suspension technology BILSTEIN
Suspension technology
Chapter 1
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 enginee-
ring. At BILSTEIN, customer requirements and our dedication
to motor sports drive development and innovation.
6 | 7 Suspension technology BILSTEIN
Suspension technologyWhat 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 con-
tact 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.
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 com-
ponent is attached to the rear axle.
8 | 9 Suspension technology BILSTEIN
Transverse forces
Long
itudi
nal f
orce
s
Basic function – strut
Lightweight construction is of great impor-
tance 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.
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 redesig-
ned. 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!
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 ab-
sorbtion. 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 %.
10 | 11 Suspension technology BILSTEIN
75 %
25 %
12 | 13 Technology transfer BILSTEIN
Technology transfer from original equipment manu-facturing and motor sports
Chapter 2
14 | 15 Technology transfer BILSTEIN
Technology transferfrom original equipment manu-facturing 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 | 17 Gas pressure shock absorbers BILSTEIN
Gas pressure shock absorbers
Chapter 3
Basic principle
The oil column of the mono-tube gas pressu-
re shock absorber is constantly pressurised
by an additional gas volume separated by a
dividing piston.
Gas pressure shock absorbers
18 | 19 Gas pressure shock absorbers BILSTEIN
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
Ove
rpre
ssur
e
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 separa-
ted 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.
Gas pressure shock absorber,
no foaming
Non-pressurised shock
absorber, foaming
How can you recognise a gas pressure shock absorber?
The piston rod extends of its own accord when the shock absorber
is disassembled.
20 | 21 Twin-tube technology vs. mono-tube technology BILSTEIN
Twin-tube tech-nology vs. mono-tube technology
Chapter 4
22 | 23 Twin-tube technology vs. mono-tube technology BILSTEIN
Twin-tube technologyvs. 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.
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.
24 | 25 Twin-tube technology vs. mono-tube technology BILSTEIN
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
Oil
150o C
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.
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
150o COil
Gas
26 | 27 Twin-tube technology vs. mono-tube technology BILSTEIN
ratios:
General formula for calculating the effective piston surface AW
A =(33,07)2
4–
(21,98)2
4
= 858,94 mm2 379,44 mm2–
= 479,49 mm2 effective piston surface
Aw
d1 Ø working piston
d2 Ø piston rodAw =
d12
4–
d22
4
Competitor, front axle (twin-tube)
Calculation of the pressure (with constant force)
P =2.000 N
479,49 mm24,171
N
mm2
F
A = 41,71 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, consi-
derably reducing wear and the risk of leaks and ensuring long-term
reliability.
BILSTEIN front axle (mono-tube)
A =(35,56)2
4–
(13,98)2
4
= 993,15 mm2 153,50 mm2–
= 839,65 mm2 effective piston surface
P =2.000 N
839,65 mm22,382
N
mm2
F
A = = 23,82 bar
Calculation of the pressure (with constant force)
=
28 | 29 Twin-tube technology vs. mono-tube technology BILSTEIN
Overviewof the advantages*
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 mm2 479,49 mm2
Effective surface of the working piston, rear axle
1504,79 mm2 597,2 mm2
The bottom line
durability. The lower working pressures reduce wear and improve setting characteristics.
A BILSTEIN technology comparison
Chrome layer – piston rod hardness, front axle
61–63 HRC 45–47 HRC
Chrome layer – piston rod hardness, rear axle
61–62 HRC 44–45 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.
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
Rebound separate from compression
Adjustment range
10 clicks for better/greater kingpin inclination
Up to 18 clicks (rebound)Up to 12 clicks (compression)
Adjustment handling
One rotation Three rotations
Compression and rebound
adjuster on each shock absorber
Rebound stage setting problematic
because there is only one adjuster
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 | 31 upside-down technology BILSTEIN
BILSTEIN upside-down technology
Chapter 5
BILSTEIN-upside-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 perfor-
mance is improved through the non-use of stainless steel to produce
the stand tube and the use of a large chrome tube.
32 | 33 upside-down technology BILSTEIN
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
The bottom line:
Thanks to its technological features, BILSTEIN upside-down tech-
nology ensures highly dynamic yet comfortable vehicle handling.
The vehicle feels extremely compact and can be easily controlled
in any driving situation.
34 | 35 upside-down technology BILSTEIN
How can I recognise upside-down technology?
The chrome tube is clearly visible at the top of the suspension strut.
Comparison mono-tube vs. twin-tube
36 | 37 Adjustment systems BILSTEIN
Adjustment systems
Chapter 6
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.
38 | 39 Adjustment systems BILSTEIN
Manual adjustment systems
Compression and rebound stage with a single turn
8 95 6
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.
Stage 1
Stage 2
Stage 3
Stage 4
Stage 5
Stage 6
Stage 7
Stage 8
Stage 9
Stage 10
Characteristic curve diagram, BILSTEIN B16
Rebound stage Speed [mm/s]
Rebound
Compression stage
Sus
pens
ion
forc
e [N
]
8 95 6
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 separa-
tely 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.
40 | 41 Adjustment systems BILSTEIN
Manual adjustment systems
Separate compression and rebound forces
42 | 43 Adjustment systems BILSTEIN
Electronic adjustment systems
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 every-
day driving pleasure.
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 exclu-
sive 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.
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 | 45 Adjustment systems BILSTEIN
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.
Finest measuring technology for perfect switching
The “auto” mode selects a suspension setting depending on
the driving conditions that the highly sensitive sensor techno-
logy 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 | 47 Height adjustment at BILSTEIN level BILSTEIN
Height adjustmentat BILSTEIN level
Chapter 7
48 | 49 Height adjustment at BILSTEIN level BILSTEIN
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.
40 mm 60 mm
30 mm 30 mm
30-50 mm 30–50 mm
The wedge-shaped suspension
Uniform lowering
The BILSTEIN threaded ride high adjustable kit
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 absor-
bers 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’ protecti-
ve 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.
50 | 51 Height adjustment at BILSTEIN level BILSTEIN
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.
+20
–20
52 | 53 Road test BILSTEIN
Road testChapter 8
Perfection is a matter of settings
suspension engineers use high-end technologies and high perfor-
mance components to develop suspensions that provide pure driving
pleasure.
54 | 55 Road test BILSTEIN
Road test
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 | 57 The product range as a whole BILSTEIN
The product range as a whole
Chapter 9
The product range as a whole
The perfect range of products for every need
58 | 59 The product range as a whole BILSTEIN
60 | 61 The product range as a whole BILSTEIN
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.
BILSTEIN B1–B4 Universal spare parts
62 | 63 The product range as a whole BILSTEIN
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.
BILSTEIN B6–B8 High-performance shock absorbers
64 | 65 The product range as a whole BILSTEIN
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.
BILSTEIN B12–B16 Sport and threaded ride high adjustable kits
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
BILSTEIN B16 ridecontrol®, DampTronic® and iRCElectronic suspensions
66 | 67 The product range as a whole BILSTEIN
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 tech-
nological requirements from the world of motor sports.
BILSTEIN Clubsport Racing and road driving in one
68 | 69 The product range as a whole BILSTEIN
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.
BILSTEIN motor sportsMotor sport suspensions
70 | 71 The product range as a whole BILSTEIN
07.2
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Your suspension specialist:
ThyssenKrupp Bilstein GmbHMilsper Straße 214, D-58256 EnnepetalPostfach 1151, D-58240 Ennepetal +49 (0)2333 791-0 +49 (0)2333 [email protected]
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