The suspension spring compression introduce local deformation in the suspension shock tower, and it brings the imprecision or uncertainty of the computer aided tolerancing (CAT) results of the suspension assembly. This work presents an integrated tolerancing and motion error analysis method of suspension assembly to consider the local deformation in the suspension shock tower. Tolerancing model of the suspension assembly is constructed in CAT software. FEA model provides the local deformation in the suspension shock tower introduced by the suspension spring compression under full loaded condition. The local deformation is represented with the modified probability distribution function (PDF) of the joining point between the suspension and the suspension shock tower. The modified PDFs of the joining points, together with the manufacturing deviations of the suspension parts are input to the constructed tolerancing model. The results are obtained that the final assembly variations of the suspension assembly under empty and full loaded conditions. Based on the tolerancing results, motion errors of the suspension from empty condition to full loaded condition are analyzed with the ADAMS model of the suspension. The results have shown that tolerancing and motion error analysis results considering the local deformation in suspension shock tower are more accurate than the initial normal distribution. The tolerancing and motion error analysis work presented in the paper will enhance the understanding of the suspension assembling, and help systematically improving the precision control efficiency in automobile industry.

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