New damper system

Reduce fuel consumption with potholes

Audi is working on a prototype called eROT, in which electromechanical rotary dampers replace the previous hydraulic dampers. This allows kinetic energy to be converted into electricity instead of heat.

The structure of the eROT system.

© Audi

Every pothole, every bump, every bend brings kinetic energy into the car, which is absorbed by the current dampers and lost in the form of heat. With the new electromechanical damper system in the 48-volt on-board electrical system, this energy is now to be utilized: The eROT system can convert kinetic energy into electricity during compression and rebound. To do this, the movements of the wheel carrier are absorbed by a lever arm. This transfers the movements via a gearbox to an electric motor, which converts them into electricity. In test operation on German roads, the recuperation power averages 100 to 150 watts - from three watts on a freshly asphalted highway to 613 watts on a bumpy side road. In customer driving, this corresponds to CO2 savings of up to three grams per kilometer.

The new eROT technology is based on a 48-volt on-board electrical system that provides a high level of power. In the first expansion stage, its lithium-ion battery offers 0.5 kilowatt hours of energy capacity and 13 kilowatts of peak power. A DC/DC converter connects the 48-volt partial on-board electrical system with the 12-volt main on-board electrical system, in which a power-boosted generator operates.

The eROT system is also designed to respond quickly and with low inertia. As an actively adjustable damping system, it adapts to uneven road surfaces and the driver's driving style. A damper map that is largely freely definable via software extends the range of functions. It eliminates the interdependence of rebound and compression damping, which restricts conventional hydraulic dampers. According to Audi, eROT allows the compression stage to be set comfortably soft during compression without compromising the firm damping of the rebound stage during extension. Another advantage is the geometry of the new damper system. The horizontally arranged electric motors in the rear axle area replace the upright telescopic shock absorbers - which also benefits the luggage compartment.

According to Audi, the initial test results of the eRot technology are very promising and therefore a future series application in Audi models is quite conceivable. The prerequisite for this is the 48-volt on-board electrical system, which is a central component of Audi's electrification strategy. In the second expansion stage planned for 2017, the 48-volt system will become the main electrical system in a new Audi model and feed a powerful mild hybrid drive.

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