What really matters! - BILSTEIN · 28 | 29 Twin-tube technology vs. mono-tube technology BILSTEIN Overview of the advantages* Mono-tube Twin-tube System type Mono-tube Twin-tube Pressurisation

What really matters!

2 | 3 Content BILSTEIN

Contents

1

2

3

4

5

6

7

8

9

Suspension technology 4–11

Technology transfer from original

equipment manufacturing and motor sports 12–15

Gas pressure shock absorbers 16–19

Twin-tube vs. mono-tube technology 20–29

BILSTEIN upside-down technology 30–35

Adjustment systems 36–45

Height adjustment at BILSTEIN level 46–51

Road test 52–55

The product range as a whole 56–71

4 | 5 Suspension technology BILSTEIN

Suspension technology

Chapter 1

Motivation

From motor sports and original equipment manufacturing to

tuning and universal spare parts – BILSTEIN is synonymous

with top quality and high performance in suspension enginee-

ring. At BILSTEIN, customer requirements and our dedication

to motor sports drive development and innovation.


Suspension technologyWhat does it mean?

Motor sport technology for everyday roads

It’s not just engine power and driving ability but also a

vehicle’s driving dynamics that are vital to success in motor

sports. A crucial role is played by the heart of the suspensi-

oversteer and understeer.

In motor sports, extremely high speeds together with bumpy

tracks, radical curb riding and rapid load changes subject

shock absorbers to extreme stresses and strains. But drivers

who want to experience sporty driving with their own vehicles

also have to be able to depend on the right components.

Whether in an everyday situation or on the Nürburgring’s

technology quickly becomes clear.

Road grip – traction – comfort

As the link between the road and the car body, the

suspension’s task is to reduce the vibrations from the wheels

( unsprung masses) and the car body in as controlled a

manner as possible.

Every attempt must be made to prevent these vibrations from

being transmitted to the car body in order to reduce rocking

and pitching, prevent swaying and ensure optimum road con-

tact and traction with minimum slip. If a vehicle’s suspension

travel on an uneven surface were reduced to zero, it wouldn’t

be possible to drive the vehicle. The result would be a great

loss of both traction and comfort.

Damped

Undamped

Vibration absorption

The vibration absorber is an energy converter

that transforms kinetic energy into thermal

-

ned valve passages in the shock absorber

piston slow the piston rod down as the oil

Basic function – shock absorber

The task of the shock absorber, or more

precisely the vibration absorber, is to reduce

the vertical vibrations of the car body and the

wheels. It doesn’t perform any directional

control tasks. With most vehicles, this com-

ponent is attached to the rear axle.


Transverse forces

Long

itudi

nal f

orce

s

Basic function – strut

Lightweight construction is of great impor-

tance in automotive design. As a result,

the McPherson strut was developed. While

a shock absorber is only subject to tensile

and compressive forces when the vehicle is

compressed or rebounds, the strut is subject

to a much higher degree of stress. The strut

helps control the wheels and is subjected to

additional lateral and transverse forces when

cornering, braking and accelerating.

Lowering and sport suspensions –

pure driving pleasure!

Drivers who lower their vehicles want dynamic

vehicle handling, along with a unique, sporty

look and perfect road holding. Achieving these

ring amount and the use of high performance

technology so as to deliberately reduce

suspension travel and change the vehicle

dynamics and axis geometry. When reducing

the suspension travel, the spring and shock

absorber forces must be completely redesig-

ned. As this kind of suspension is subject to

higher loads, high performance components

are essential. Complete suspensions by

BILSTEIN are the ideal solution – for pure

driving pleasure!

Interaction between the spring

and the shock absorber

When traversing an obstacle, the initial forces

impact on the spring. Its function must not

be impaired by a high degree of shock ab-

sorbtion. Once the spring has compensated

for the obstacle, the shock absorber must

slow the motion of the forcefully released

spring. To do this, it provides compression

and rebound forces in a ratio of approx.

25 % : 75 %.


75 %

25 %

12 | 13 Technology transfer BILSTEIN

Technology transfer from original equipment manu-facturing and motor sports

Chapter 2

14 | 15 Technology transfer BILSTEIN

Technology transferfrom original equipment manu-facturing and motor sports

The goal

To take all of the insights gained from original equipment

manufacturing for companies such as BMW, Mercedes-Benz,

Aston Martin, Land Rover, Nissan, Bugatti and Porsche as well

as from the extensive involvement in endurance racing at the

Nürburgring, the Baja races in California and Formula 3 racing,

and transfer them 1 : 1 into the BILSTEIN product range.

The requirement

Motor sport teams’ need for a suspension that could be

optimally adapted to race tracks with widely varying demands

led to BILSTEIN developing threaded ride high adjustable kits

almost 40 years ago. The requirements were clear: stress-free,

perfect driving performance in every situation, uncompromising

handling, solid shock absorption right from the start and a high

degree of reliability.

Uncompromising solutions

The technology developed and continually enhanced by BIL-

STEIN engineers precisely met these requirements. From gas

pressure, mono-tube and upside-down technology to parallel

shock absorption adjustment: the right technologies are used in

the right situations to yield the ideal product.

16 | 17 Gas pressure shock absorbers BILSTEIN

Gas pressure shock absorbers

Chapter 3

Basic principle

The oil column of the mono-tube gas pressu-

re shock absorber is constantly pressurised

by an additional gas volume separated by a

dividing piston.

Gas pressure shock absorbers

18 | 19 Gas pressure shock absorbers BILSTEIN

Pressure differences

All shock absorber oil contains about 10 %

gaseous air in a molecular bound state.

The movements of the shock absorber

piston within the oil column cause pressure

When the piston rod is thrust abruptly into

the shock absorber interior due to an uneven

road surface, pressure rises in front of the

piston and falls behind the piston.

Oil

Gas

Ove

rpre

ssur

e

Loss in performance

bubbles form (foaming). On longer drives the foaming in the shock

absorber oil can be so great that the suspension force is considerably

reduced – sometimes by as much as up to 35 %. The shock absorber

no longer provides good shock absorption. The wheels lose road grip;

traction and driving dynamics are majorly impaired.

Performance pressure

The nitrogen gas in a gas pressure shock absorber, which is separa-

ted from the oil by a dividing piston, keeps the oil column pressurised,

thus preventing the release of the shock absorber oil’s gas molecules

(foaming).

The bottom line:

Only gas pressure shock absorbers offer drivers constant shock

absorption in every driving situation.

Gas pressure shock absorber,

no foaming

Non-pressurised shock

absorber, foaming

How can you recognise a gas pressure shock absorber?

The piston rod extends of its own accord when the shock absorber

is disassembled.

20 | 21 Twin-tube technology vs. mono-tube technology BILSTEIN

Twin-tube tech-nology vs. mono-tube technology

Chapter 4


Twin-tube technologyvs. mono-tube technology

The challenge

When kinetic energy is converted into thermal energy, temperatures of

up to 150°C can be generated while driving. This thermal energy must

be dissipated to prevent a loss of performance and possible failure.

Twin-tube technology

More than 90 % of all series production vehicles

are equipped with twin-tube shock absorbers.

When using this double-walled shock absorption

system, the thermal energy generated cannot

be directly dissipated into the environment.

The working piston located in the inner shock

absorber tube can assume the diameter of the

inner shock absorber tube as a maximum. The

small working piston diameter and the resultant

of great pressures that in turn cause increased

wear.


Twin-tube technology at a glance:

Two tubes �

� Greater wear

High thermal load Loss of performance

Foaming Loss of performance

Short service life

Installation position only up to max. 45°

Greater tolerances

Low overall length at the same stroke in comparison with

mono-tube

outer tube Inner wall has no functional surface

Oil

150o C

Mono-tube technology

standard in motor sports as well as in luxury

sports cars. The perfect drive performance of

these systems speaks for itself. Mono-tube shock

absorbers are only available as gas pressure

shock absorbers. With this single-walled shock

absorption system, the thermal energy generated

in the shock absorber is directly dissipated into

generated by the large working piston. At the

same time, high suspension forces are available,

ensuring constant, high shock absorption. The

gas pressure prevents the oil from foaming. The

-

sion engineers are always available and ensure

perfect, dynamic drive performance.

Mono-tube technology at a glance:

One tube Direct heat dissipation

No overheating Required suspension power always available

Installation independent of position Upside-down design

possible with suspension struts

Large working piston

�

Greater production accuracy Higher costs

150o COil

Gas


ratios:

General formula for calculating the effective piston surface AW

A =(33,07)2

4–

(21,98)2

4

= 858,94 mm2 379,44 mm2–

= 479,49 mm2 effective piston surface

Aw

d1 Ø working piston

d2 Ø piston rodAw =

d12

4–

d22

4

Competitor, front axle (twin-tube)

Calculation of the pressure (with constant force)

P =2.000 N

479,49 mm24,171

N

mm2

F

A = 41,71 bar = =

The bottom line:

Better handling, greater comfort, high safety reserves. BILSTEIN

mono-tube shock absorbers can be perfectly tuned to every type of

load.

With BILSTEIN mono-tube technology, the larger effective surface

decreases the pressure in the shock absorber by nearly half, consi-

derably reducing wear and the risk of leaks and ensuring long-term

reliability.

BILSTEIN front axle (mono-tube)

A =(35,56)2

4–

(13,98)2

4

= 993,15 mm2 153,50 mm2–

= 839,65 mm2 effective piston surface

P =2.000 N

839,65 mm22,382

N

mm2

F

A = = 23,82 bar

Calculation of the pressure (with constant force)

=


Overviewof the advantages*

Mono-tube Twin-tube

System type

Mono-tube Twin-tube

Pressurisation

Gas pressure Gas pressure

Effective surface of the working piston, front axle

845,24 mm2 479,49 mm2

Effective surface of the working piston, rear axle

1504,79 mm2 597,2 mm2

The bottom line

durability. The lower working pressures reduce wear and improve setting characteristics.

A BILSTEIN technology comparison

Chrome layer – piston rod hardness, front axle

61–63 HRC 45–47 HRC

Chrome layer – piston rod hardness, rear axle

61–62 HRC 44–45 HRC

Piston rod surface roughness, front axle

0,29 μm 0,32 μm

Piston rod surface roughness, rear axle

0,28 μm 0,32 μm

Piston rod chrome thickness, front axle

34,2–36,2 μm 27,1–32,5 μm

Piston rod chrome layer thickness, rear axle

33,4–35,8 μm 27,8–31,6 μm

The bottom line

The higher quality of the materials used and the outstanding workmanship ensure extreme reliability when using our products.

Mono-tube Twin-tube

Material type

Precision steel tube Normal stainless steel

The bottom line

The use of precision steel instead of normal stainless steel preserves the basic elasticity of the shock absorber tube, preventing the risk of oil loss and shock absorber failure.

Adjustment type

Simultaneous compression and rebound

Rebound separate from compression

Adjustment range

10 clicks for better/greater kingpin inclination

Up to 18 clicks (rebound)Up to 12 clicks (compression)

Adjustment handling

One rotation Three rotations

Compression and rebound

adjuster on each shock absorber

Rebound stage setting problematic

because there is only one adjuster

for all of the shock absorbers

Assessment

Adjustment range recorded Fixed measurement recorded

The bottom line

In contrast to the competition, you always achieve the right adjustment when handling the BILSTEIN shock absorber. With three rotations, click division is not useful.

requirements more easily and precisely.

* Based on an example of a threaded ride high adjustable kit with suspension force adjustment.

30 | 31 upside-down technology BILSTEIN

BILSTEIN upside-down technology

Chapter 5

BILSTEIN-upside-down technology

Suspension struts

Suspension struts are shock absorption systems that simultaneously

guide the wheel and absorb vibrations.

Upside-down technology

High-performance struts are built into mono-tube technology. Known

as BILSTEIN upside down technology, this was developed for motor

sports where it now dominates. The lower end of the piston rod is

attached into the tube body. The wear-resistant chrome tube moves

up and down on slide bearings distributing the restoring and lateral

Noticeable difference

The high transverse forces that also occur during high performance

This in turn reduces driving safety and performance. With its special

design, the BILSTEIN upside-down suspension strut provides series

safety and comfort. On installing this system, the improvements in

driving stability are instantly perceptible. Moreover, the drive perfor-

mance is improved through the non-use of stainless steel to produce

the stand tube and the use of a large chrome tube.


BILSTEIN upside-down suspension strut

The large chrome tube can absorb extreme transverse

forces

The mono-tube technology ensures direct dissipation of

thermal energy

Due to the large outer diameter of the chrome tube, little

selective friction occurs

Careful material selection (no stainless steel) guarantees

controlled, dynamic responses

during both compression and rebound

The large working piston ensures maximum suspension

force, optimum setting and low thermal loads

The piston rod is not subject to any transverse forces

The shock absorption system is protectively located inside

the suspension strut

The bottom line:

Thanks to its technological features, BILSTEIN upside-down tech-

nology ensures highly dynamic yet comfortable vehicle handling.

The vehicle feels extremely compact and can be easily controlled

in any driving situation.


How can I recognise upside-down technology?

The chrome tube is clearly visible at the top of the suspension strut.

Comparison mono-tube vs. twin-tube

36 | 37 Adjustment systems BILSTEIN

Adjustment systems

Chapter 6

In creating the shock absorbers in the BILSTEIN B16 series, BILSTEIN

engineers have established a new performance class. 9/10 charac-

absorbers’s performance in the rebound and compression stage

as exact and parallel. When installed, these stored settings can be

precisely selected with a single turn of the aluminium wheel – a clear

click indicates the correct setting. There are ten clicks in one rotation

of the setting wheel.


Manual adjustment systems

Compression and rebound stage with a single turn

8 95 6

Correct setting is assured

Depending on the wheel/tyre combination ( unsprung masses) or

driving situation, drivers can adjust the BILSTEIN B16 setup to meet

their individual needs. The compression and rebound stages of the

BILSTEIN B16 always correspond perfectly with each other for pure

driving pleasure.

The simultaneous suspension force adjustment (simultaneous

adjustment of the compression and rebound stages) is only

possible with high quality mono-tube systems.

Stage 1

Stage 2

Stage 3

Stage 4

Stage 5

Stage 6

Stage 7

Stage 8

Stage 9

Stage 10

Characteristic curve diagram, BILSTEIN B16

Rebound stage Speed [mm/s]

Rebound

Compression stage

Sus

pens

ion

forc

e [N

]

8 95 6

Your customised setting

Our premium quality BILSTEIN Clubsport threaded ride high

adjustable kits meet the highest of the high demands in motor

misable. Compression and rebound forces can be set separa-

tely using highly visible setting wheels with clear scales.

Quick, precise and professional

Changing the setup here is as easy as pie with 10 x 10 clearly

perceptible clicks. This enables drivers to create their own

characteristic curve combinations between soft (1) and hard

(10).

Perfect control

Using the camber adjustment, these characteristic variations,

together with the supplied uniball supporting bearings, make

it possible to select the optimum setup for the road surface,

weather conditions, vehicle weight, tyre and aerodynamic

parameters and driver characteristics.


Manual adjustment systems

Separate compression and rebound forces


Electronic adjustment systems

The bottom line:

The perfect setting depends on the ability to individually

adjust the most important parameters. BILSTEIN provides

key technologies from the world of motor sport for every-

day driving pleasure.

BILSTEIN B16 ridecontrol®

In full control

If you don’t want to make any compromises on the road, you

have to have everything under control. Ideally, this means in

your vehicle cockpit. BILSTEIN ridecontrol® provides an exclu-

sive setting system at the touch of a button. You can switch

from comfortable to sporty driving quickly and conveniently

from inside your vehicle.innen steuerbar.

BILSTEIN B16 DampTronic®

Uncompromising dynamics

We provide an exclusive power class for owners of BMWs,

special qualities of an active suspension through the use of

the BILSTEIN B16 DampTronic®. This is perfectly adapted to

the series-production electronic adjustment system while also

drivers enjoy improved road grip and greater tracking stability

for comfortable everyday driving and extreme sport situations.

The already outstanding driving dynamics are even further

enhanced through the retention of the EDC and PASM..

The bottom line:

At the touch of a button you can adapt your exclusive,

active suspension to your individual needs and further

improve the drive performance.


BILSTEIN B16 iRC

Active adjustment with that certain touch

The well-known BILSTEIN ridecontrol® system for suspension

control has been further enhanced with a convenient feature:

control by iPhone app. Instead of the familiar button (switch),

an iPhone can now be used to set the system with iRC.

Drivers can switch between the basic modes “comfort+” and

“sport+”. With famous BILSTEIN precision, the “comfort+”

mode smoothly compensates for bumpy road surfaces while

the “sport+” mode ensures excellent driving dynamics and

optimum power reserves when driving at the limit.

Finest measuring technology for perfect switching

The “auto” mode selects a suspension setting depending on

the driving conditions that the highly sensitive sensor techno-

logy reports to the control unit. The sensor sensitivity can be

acceleration thresholds and, above all, the control intervals.

programming results on the iPhone screen makes manually

conducting settings easy.

46 | 47 Height adjustment at BILSTEIN level BILSTEIN

Height adjustmentat BILSTEIN level

Chapter 7


Height adjustment at BILSTEIN level

Lowering at the highest level

Lowering is a question of character with respect to both the vehicle

and the driver. Based on extensive testing experiences, our test

The wedge-shaped suspension

Lowering of approx. 60 mm at the front axle and approx. 40 mm at

the rear axle creates a highly sporty appearance that packs a huge

visual punch.

Uniform lowering

Lowering the entire vehicle by approx. 30 mm emphasises the driving

dynamics without compromising on comfort or suspension travel.

The BILSTEIN threaded ride high adjustable kit

This version of lowering allows smooth and variable tuning in line with

your desired balance between sporty characteristics and comfort.

40 mm 60 mm

30 mm 30 mm

30-50 mm 30–50 mm

The wedge-shaped suspension

Uniform lowering

The BILSTEIN threaded ride high adjustable kit

The right level

Threaded height adjustment makes it possible to adapt the car body

height and vehicle balance to drivers’ needs. Level corrections of up to

20 mm with our threaded ride high adjustable kits have already been

TÜV registered. The perfectly designed combination of shock absor-

bers and springs guarantees ideal spring pre-tension with optimum

suspension travel over the entire adjustment range. The spring plates

and lock nuts are made from aluminium. The threaded tubes’ protecti-

ve coating exceeds the applicable DIN standards and the requirements

of the automotive industry and ensures durable adjustability.

Air suspension

Perfect support for the functionality of the vehicle manufacturer’s

active suspension systems.


The bottom line:

Both in motor sports and on the roads – the right combination of

applied technology and optimum material selection, vehicle height,

spring rate and shock absorber setting is crucial for your driving

pleasure and success. BILSTEIN offers perfection at the highest

level.

+20

–20

52 | 53 Road test BILSTEIN

Road testChapter 8

Perfection is a matter of settings

suspension engineers use high-end technologies and high perfor-

mance components to develop suspensions that provide pure driving

pleasure.

54 | 55 Road test BILSTEIN

Road test

Road tests

The typical BILSTEIN tuning is tested in extensive road tests. BILSTEIN

suspensions are tuned and tested to the limit on the Mercedes-Benz

test track in Papenburg and the legendary Nürburgring Nordschleife,

the toughest race course in the world. Several test drivers put the sus-

the optimum settings. As the test conditions always remain the same,

the test results can be reliably compared.

The test phase

High speed, lane changes, comfort, handling, vehicle balance,

traction: during the test phase, the suspension must meet demands in

all of these areas. And only if all the high BILSTEIN requirements are

met does the suspension come onto the market in series production.

After all, it’s when you’re pushing it to the limit that a perfectly tuned

suspension becomes critical to driving pleasure and safety.

Bottom line:

Technology, perfection and experience result in driving dynamics

and safety.

Hydropulser

56 | 57 The product range as a whole BILSTEIN

The product range as a whole

Chapter 9

The product range as a whole

The perfect range of products for every need



BILSTEIN technology for almost every type of vehicle. With

sion components for every driver – and every wallet size. Of

course, the parts come in high OEM quality and incorporate

BILSTEIN’s years of experience.

BILSTEIN B1–B4 Universal spare parts


Drivers who have experienced our high-performance shock

absorbers know how much untapped power is available from

their vehicles. Whether meeting your demands for sporty

handling or withstanding frequent driving under heavy

loads, with these yellow BILSTEIN components your vehicle

is certain to excel itself.

BILSTEIN B6–B8 High-performance shock absorbers


With BILSTEIN sport and threaded ride high adjustable kits

you will experience new dimensions in sporty driving. A

unique appearance, a customised look and vehicle handling

tailored to your own requirements – enjoy every road, every

curve and every inch of asphalt.

BILSTEIN B12–B16 Sport and threaded ride high adjustable kits

a button. World class technology for anyone who refuses to

compromise – in life or on the road. Press the button to switch

instantly from comfortable to sporty – and back again.

BILSTEIN B16 iRC – the BILSTEIN app for active suspension

control

BILSTEIN B16 ridecontrol®, DampTronic® and iRCElectronic suspensions


The BILSTEIN Clubsport suspension is the high-end, threaded

and is also designed for uncompromising use in racing and

club sports. The suspension combines the proven BILSTEIN

mono-tube gas pressure technology with the highest tech-

nological requirements from the world of motor sports.

BILSTEIN Clubsport Racing and road driving in one


When used in racing vehicles, our BILSTEIN motor sport

suspensions ensure maximum contact between the wheels

and the race course. Many racing teams trust in the

BILSTEIN MDS suspension with an adjustable compression

and rebound stage and, in so doing, secure their podium

positions.

BILSTEIN motor sportsMotor sport suspensions


07.2

013

· W-8

0053

9 · S

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Your suspension specialist:

ThyssenKrupp Bilstein GmbHMilsper Straße 214, D-58256 EnnepetalPostfach 1151, D-58240 Ennepetal +49 (0)2333 791-0 +49 (0)2333 [email protected]

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Documents

What really matters! - BILSTEIN · 28 | 29 Twin-tube technology vs. mono-tube technology BILSTEIN Overview of the advantages* Mono-tube Twin-tube System type Mono-tube Twin-tube Pressurisation