Leaf Spring Design Using Pressure Distribution

Measure, view, and evaluate dynamic forces acting between a leaf spring and contact surface.

Leaf Spring Design, Test, and Validation Using Pressure Distribution

The I-Scan^® pressure measurement system is an extremely versatile tool for leaf spring applications. Because of the sensor’s unique, thin design (> 0.1mm thick), measurements can be made quickly between two or more mating leaf springs simultaneously. Once the sensor is in place, dynamic measurements can be taken while the load on the vehicle is increased.

This can be useful for all aspects of leaf spring designs including the selection of materials, assembly techniques and optimization of the clamp design.

Leaf Spring Pressure Profile Leaf Spring Force vs. Time Graph

2-D output of leaf spring showing high pressure on the outside of the loaded spring (left). Force vs. Time graph showing the incremental forces as weight is loaded onto the vehicle (right).

Leaf Spring Pressure Measurement Applications

R&D investigations
New product design
Quality control
Assembly Inspections

Benefits of Pressure Mapping

Brings real contact forces into leaf spring design
Assists in leaf spring wear prediction by identifying location of contact loads as a function of vehicle weight
Can better choose the optimum liner materials
Can evaluate different construction materials

Typical Pressure Sensors used for Leaf Spring Evaluation

Sensor Model 5101

Sensing Area Total

Width Height Sensels Sensel Density

4.40 in. 4.40 in. 1,936 100.0 in.²

111.8 mm 111.8 mm 1,936 15.5 cm²
Sensor Model 5511

Sensing Area Total

Width Height Sensels Sensel Density

12.10 in. 3.40 in. 1,496 36.4 in.²

307.3 mm 86.4 mm 1,496 5.6 cm²
Sensor Model 6077

Sensing Area Total

Width Height Sensels Sensel Density

3.75 in. 2.10 in. 1,400 177.8 in.²

95.2 mm 53.3 mm 1,400 27.6 cm²