Design Framework for Ground-Vehicle Suspension Actuators Using Digital Twin Technology

Ground-vehicle manufacturers and their suppliers must shorten development cycles to remain competitive. This paper presents a novel design framework that accelerates the traditional V-model development lifecycle by enabling digital twins and hardware-in-the-loop testing. As a case study, the design of active suspension actuators to address comfort shortfalls that hinder automated driving has been selected. A hybrid suspension architecture combining a continuously controlled hydraulic damper with an auxiliary electromechanical actuator has been proposed. The hybrid system achieves lower energy consumption than purely electromechanical suspensions while overcoming the bandwidth limitations of conventional hydraulic active suspensions. Control is implemented using the Triple Skyhook algorithm and benchmarked against a baseline strategy. Results demonstrate that the proposed framework accelerates actuator design iteration and that the proposed suspension delivers superior performance with improved efficiency and bandwidth.