Design and Development of an Innovative Two-Degree-of-Freedom Rear Suspension System for Reverse Trikes

This paper presents the research, development, and functional validation of an original rear suspension system designed for hybrid reverse trike vehicles (two guided wheels on the front axle and a twin-tire-driven assembly at the rear). Conventional configurations featuring a single rear wheel exhibit severe limitations regarding lateral stability under critical dynamic regimes and induce roll-induced torsional loading in flexible chain drives. The proposed solution utilizes a twin-tire rear assembly integrated into an articulated suspension mechanism with two degrees of freedom (2 DoF), which reconfigures the geometric stability polygon from a triangle into an isosceles trapezoid. A mathematical model based on tire dynamics and tire slip phenomena demonstrates that introducing a controlled roll stiffness on the rear axle stabilizes the slip angles, ensuring a neutral and predictable steering behavior. Structural validation via finite element analysis (FEA) performed in SOLIDWORKS Simulation on the entire assembly under a conservative combined load scenario (2400 N vertical force shared by the two wheel bearings, 2400 N lateral force, and 1200 N tractive force) indicated a minimum factor of safety of 1.26 on S275N structural steel, confirmed by an eleven-run mesh independence study. Finally, the system’s functionality was experimentally confirmed through the manufacturing and road testing of a full-scale (1:1) demonstrator vehicle powered by an 1129 cc Boxer engine, highlighting a measurable increase in rollover resistance and trouble-free operation of the two-stage chain drive throughout the test program. A numerical evaluation shows that for rear-biased vehicles of the category the proposed axle raises the rollover-related lateral acceleration threshold by up to 54% and replaces the strongly oversteering balance of the single-wheel layout with a near-neutral, tunable one.