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.

This paper presents an iterative graph-analytical procedure for determining the roll center height, one of the most critical design parameters influencing vehicle dynamic behavior during cornering. The conventional approaches generally determine roll center locations from suspension kinematics and then evaluate vehicle behavior using multibody or numerical vehicle dynamics models. By contrast, the proposed method is intended for the preliminary design stage and provides a direct correlation between front and rear target roll center heights using tire test data, load transfer and axle-level equilibrium conditions. The main advantage of the method is that it helps define a feasible design space before detailed geometry optimization or MBD validation is performed. The objective is to achieve stable and neutral handling (avoiding intrinsic understeer or oversteer tendencies) during steady-state cornering at a predefined target lateral acceleration. The methodology integrates (i) lateral force equilibrium at the axle level, (ii) a dynamic load transfer model based on axle roll stiffness and roll center heights, and (iii) experimental tire grip characteristics (lateral force–slip angle curves under varying vertical loads), processed through numerical interpolation. The procedure is demonstrated using a vehicle model with specific geometric and mass parameters. The results indicate that the methodology does not yield a single unique solution, but rather a set of correlated roll center heights, allowing the designer to select the most feasible geometric configuration while maintaining neutral handling. As an example, the paper presents a convergent solution for the front and rear roll center heights that satisfy neutrality conditions at a slip angle of approximately 4°. This study provides a fundamental framework for the geometric design of suspension systems and serves as a basis for subsequent numerical and experimental validation.