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Active suspension systems have been used in the recent years as they provide better ride comfort, road handling and safety. The effect of vehicle vibration caused by road roughness is effectively reduced by active suspension system which plays an important role in improving the vehicle performance indices. The application of active suspension system is limited because it consumes high amount of energy. From the point of energy saving, a regenerative active suspension system is designed and its working principle with two modes switched in different conditions was implemented. In this implementation scheme, operating electric circuits are designed based on different working status of the actuator and power source. In the first stage an electromotor mode in which an active suspension system uses a linear electric actuator controlled by constrained PID controller. In the generator mode, under certain circumstances using linear motor as actuators enables to transform mechanical energy of the car vibrations to electrical energy and accumulated to charge the energy-storage capacitor and fed back into the power source when needed.

The main objective of the variable damper controlled vehicle suspension system is to reduce the discomfort identified by passengers which arises from road roughness and to increase the ride handling related with the rolling, pitching and heave movements. This imposes a very fast and accurate variable damper to meet as much control objectives, as possible. The method of the proposed damper is to reduce the vibrations on each corner of vehicle by providing control forces to suspension system while travelling on uneven road. Numerical simulations on a full vehicle suspension model are performed in the Matlab Simulink toolboxes to evaluate the effectiveness of the proposed approach. The obtained results show that the proposed system provides better results than the conventional suspension system.

In the chassis assembly shop, there are instances when the rear axle oil was not filled. During the period from January to December, there were ten such instances that were reported. Out of the 10 cases, 6 cases seized after handing over the vehicle to the customer and 4 cases were identified when the vehicles left the assembly process. The reason for the seizing of the trucks was predominantly due to the absence of the oil in the rear axle or in some cases, due to the discrepancy that occurred. This problem can be rectified by introducing the concept of interlocking, wherein the conveyor stops from proceeding to the next stage in case the rear axle oil is not filled. To prevent any further chances of error, a system was suggested where a code is scanned, which gives details of the bill of materials used to assemble the truck. This bill of material includes the axle model number which is cross referenced with a traceability matrix to determine the quantity of oil required and confirming the oil filling process with a sticker.