Fatigue analysis of a suspension for an in-wheel electric vehicle

•Development of variable amplitude loading event based on service loads by conducting experiments on the EV suspension•With rain flow counting methods to establish damage matrix and life matrix for the EV suspension•Applying Plamgren-miner rule, predicting the fatigue life cycles based identified cumulative damages to suspension

Electrical vehicles (EVs) have a significant role in reducing transportation emissions and dependence on fossil fuels. This research has developed a high energy density in-wheel switch reluctance motor (SRM) drivetrain for a small car. The SRM drivetrains overcome the cost and availability issues associated with the permanent magnet motor (PMM), mostly used in EVs. However, the in-wheel SRM developed has an increased mass on suspensions when compared with an equivalent power output PMM drivetrain. Hence, the main aim of this paper is to assess the durability and life cycles for a small car suspension due to an increased mass. This fatigue study used a rain flow counting cycle method to generate damage and life matrix for the suspension. Using Plamgren-miner rule, the fatigue life cycles are predicted based on identified cumulative damages to the suspension.