Method for manufacturing torsionally flexible axle structure

Abstract

The invention relates to a method for manufacturing an axle structure of a motor vehicle, comprising the following steps: providing a pair of first arms (45) of a first length capable of connecting two wheels and a body of a vehicle of a first type; and a pair of second arms providing a second length, the pair of second arms being capable of connecting the two wheels and the body of the vehicle of the second type. The following are provided: a plurality of pairs of longitudinal tubular members (10) having the same length, each of the tubular members having a first end (12) and a second end (14) opposite; and a pair of short sleeves (44) and a pair of long sleeves. A short sleeve (44) is mounted at a first end (12) of a tubular member of the pair of tubular members, while a long sleeve is mounted at a first end of a tubular member of the other pair of tubular members.

Description

[0001] The invention relates to a method for producing a torsion axle structure for a motor vehicle.

[0002] It is known to implement flexible axles at the rear of motor vehicles.

[0003] These axles have two parallel suspension arms connected to each other by a crossbeam. These arms have front ends hingedly mounted on anchor points on the vehicle body and rear ends equipped with wheel supports. The rear ends of the suspension arms extend toward the rear of the vehicle, while the front ends extend toward the front. Furthermore, the wheel supports accommodate the vehicle's rear wheels.

[0004] Furthermore, the suspension arm is connected to the vehicle body by means of an elastically compressible member, such as a coil spring.

[0005] Different types of vehicles can be built on a common platform, ranging from compact vehicles to heavier and more bulky vehicles. These different types of vehicles differ, for example, in their wheelbase, their track (i.e., the distance between the wheels), or their height.

[0006] Therefore, usually on the same platform: on the one hand, pairs of first arms are provided, which are connected to each other by a crossbeam and have a first length so as to be able to connect two wheels and the body of a first type of vehicle; and on the other hand, pairs of second arms are provided, which are connected to each other and have a second length longer than the first length so as to connect two wheels and the body of a second type of vehicle.

[0007] In other words, it is appropriate to design and produce two different pairs of arms for two types of vehicles manufactured on a common platform.

[0008] However, these different types of arms are relatively expensive to design and produce.

[0009] The problem that arises and that the present invention aims to solve is therefore to provide a method for producing a torsion axle structures which makes it possible to mount different types of axle structures on the same platform at more favorable costs.

[0010] To this end, a method for manufacturing a torsion axle structure for a motor vehicle is proposed, comprising the following steps: providing pairs of first arms, the pairs of first arms being connected to each other and having a first length, the pairs of first arms being designed to connect two wheels and a vehicle body of a first type; providing pairs of second arms being connected to each other and having a second length longer than the first length, the pairs of second arms being designed to connect two wheels and a vehicle body of a second type. Furthermore, a plurality of pairs of longitudinal tubular members of the same length are provided, the first end of each of the tubular members being opposite to the second end; and pairs of short sleeves and pairs of long sleeves. The short sleeves are mounted at the first ends of the tubular members in the pairs of tubular members to provide the pairs of first arms, while the long sleeves are mounted at the first ends of the tubular members in the other pairs of tubular members to provide the pairs of second arms.

[0011] Therefore, one feature of the invention is the implementation of a common part of the arm, the tubular member and the sleeves of different lengths. The sleeves are then mounted on the tubular member between the anchoring points on the wheel support and the vehicle body according to the required arm length, as will be explained below.

[0012] The sleeve is made of a metallic material, such as steel. In this way, the sleeve can be easily connected to the tubular members, which themselves are made of steel, by welding.

[0013] It will be observed that the long sleeve can also be bent according to a first curvature, for example to increase the height of the vehicle. The long sleeve can also be bent according to a second curvature in a plane substantially perpendicular to the plane defined by the first curvature, for increasing the wheelbase of the vehicle.

[0014] Thus, the tubular member and the wheel support are identical for different types of vehicles, and different sleeves are installed depending on the type of vehicle.In this way, the manufacture of a large part of the different suspension arms is standardized and its manufacturing costs are therefore reduced.

[0015] According to a particularly advantageous embodiment of the present invention, each of the pair of sleeves comprises a mounting end and a Y-shaped end opposite the mounting end, the Y-shaped end being adapted to receive a laterally extending bushing. Furthermore, the Y-shaped end is oriented such that, when the first end of the tubular member is fitted into the mounting end, the bushing can be laterally oriented in a substantially horizontal direction. The bushing, which is made of a metallic material, is then welded to the Y-shaped end of the sleeve. The bushing is made of steel, for example.

[0016] In addition to the length of the suspension arm (which is determined by the implementation of a short or long sleeve), it is also possible to attach a bushing with a small or large diameter to the sleeve. This makes it possible to connect the suspension arm to the vehicle body with the help of silent blocks of different sizes, depending on the vibration filtering required.

[0017] Furthermore, and advantageously, the mounting end is substantially cylindrical. Accordingly, the first end of the tubular member is cylindrical, and the cross-section of the mounting end is identical to the cross-section of the first end of the tubular member. In this way, the first end of the tubular member and the mounting end of the sleeve cooperate perfectly with each other. In this way, a better connection is achieved between the first end of the tubular member and the mounting end of the sleeve.

[0018] According to a particularly advantageous embodiment of the invention, the assembly end is defined by a generatrix parallel to the assembly direction, while the Y-shaped end is inclined relative to the assembly direction. The Y-shaped end thus has two branches, which are then inclined relative to the generatrix of the assembly end. This inclination makes it possible to reduce the vehicle's wheelbase to a certain extent.

[0019] According to a preferred embodiment of the present invention, two shell parts are provided, each having two opposing longitudinal edges and an arcuate edge opposite the edge of the notch, and the two parts are connected together by their two opposing edges to form each sleeve in the pair. This embodiment allows the sleeves to be produced by conventional industrial techniques of cutting and stamping followed by welding. These parts are thus obtained at a favorable cost.

[0020] Preferably, the notch edges of the two pieces define a circular shape between a semicircle and a three-quarter circle. The notch edges of the two pieces extend toward each other to form a Y-shaped end. Furthermore, the shape of the two pieces allows for easy attachment of the bushing to the two pieces. For example, the outer diameter of the bushing is substantially equal to the diameter of the notch edges of the two pieces. Furthermore, the bushing and the notch edges are advantageously welded together.

[0021] In other words, the sleeve is welded to the first end of the tubular member in order to install the sleeve.

[0022] Furthermore, advantageously, a plurality of crossbeams are provided for connecting the arms of each of the first and second pairs of arms. Preferably, the crossbeams are all identical and made of a metal material. In addition, the arms of each of the pairs of arms are connected upstream of the sleeve via a tubular member.

[0023] Advantageously, the cross beam is welded in a T-shape to each of the pair of first arms and the pair of second arms.

[0024] Furthermore, in a preferred manner, a wheel support is mounted at the second end of the tubular member in the pair of tubular members.

[0025] Further particular features and advantages of the present invention will become apparent on reading the description of specific embodiments of the invention provided below, given by way of non-limiting indication, with reference to the accompanying drawings, in which:

[0026] [ Figure 1 ] is a schematic side view of elements making it possible to implement the method according to the invention;

[0027] [ Figure 2 ]yes[ Figure 1 ] is a schematic side view of an element shown in FIG. 1 , which element is supplemented with another element according to the invention;

[0028] [ Figure 3 ]yes[ Figure 1 ] is a schematic side view of the element shown in FIG. 1 , which is supplemented with a further element according to the invention;

[0029] [ Figure 4 ]yes[ Figure 2 ] a schematic exploded perspective detail view of said further element shown;

[0030] [ Figure 5 ]yes[ Figure 4 ]; and

[0031] [ Figure 6 ] is the assembled [ Figure 4 ] is an overhead schematic diagram of the subject.

[0032] [ Figure 1 ] shows a longitudinal tubular member 10, the first end 12 of which is opposite to the second end 14. Furthermore, the second end is equipped with a motor vehicle wheel support 16.

[0033] As will be explained in more detail below, this longitudinal tubular member 10, after being assembled and installed, is inscribed in an orthogonal reference system X, Y, Z, in which the axis X extends in the longitudinal direction of the motor vehicle, oriented towards the rear; the axis Y extends in the transverse direction of the vehicle, oriented from left to right; and the axis Z extends in the vertical direction, oriented away from the ground.

[0034] The longitudinal tubular member 10 is substantially curved such that the first end 12 extends in a plane (X, Z) along a first average direction D1 that is substantially oblique relative to a second average direction D2 of the second end 14 .

[0035] Furthermore, the first end 12 of the tubular member 10 is substantially deformed and ovalized, extending along the vertical component Z.

[0036] Now refer to [ Figure 4 ]、[ Figure 5 ]and[ Figure 6 ], then return to [ Figure 1 ], then return to [ Figure 2 ].

[0037] [ Figure 4 ] shows the first right side shell 18 extending toward the first left side shell 20. The first left side shell 20 has two opposite first left longitudinal edges, namely an upper edge 22 and a lower edge 24, on the one hand, and a left curved edge 28 facing rearward, opposite to a left notch edge 30 facing forward.

[0038] Furthermore, the left notch edge 30 defines a left circular shape 32 that opens along a chord opposite the left arcuate edge 28. Thus, the circular shape has a radius R and defines a circular segment between 180° and 270°.

[0039] In contrast, the right shell 18 has two opposing first right longitudinal edges, namely a right upper edge 34 and a right lower edge 36. The right shell also has a rearwardly facing right arcuate edge 38 opposite a right notch edge 40 oriented forwardly and receiving a bushing 42.

[0040] The right notch edge 40 defines a right circular shape that is identical to and has the same radius R as the left circular shape 32 .

[0041] The outer radius of the bushing 42 approaches the radius R of the notch edge 40 so as to be able to engage through this notch edge and, as will be explained below, also through the left notch edge 30 .

[0042] [ Figure 5 ] shows[ Figure 4 ] is a top view of the subject matter of FIG, and thus shows the right shell 18 facing the left shell 20. Furthermore, it will be observed that the two shells 18, 20 are substantially curved; the right shell 18 is substantially concave, while the left shell 20 is substantially parallel convex.

[0043] this[ Figure 5 ] Also shown is a bushing 42 engaged within the right notch edge 40. Thus, the two shells 18, 20 are paired so that the first left lower edge 24 bears against the first right lower edge 36, and the first left upper edge 22 bears against the first right upper edge 34, with the bushing 42 also extending through the left notch edge 30.

[0044] A weld bead is then applied to the junction of the two first upper edges 22, 34 and the junction of the two first lower edges 24, 36 in order to secure the two first upper edges to one another and the two first lower edges to one another and to form a first sleeve 44 which then appears at [ Figure 6 ]middle.

[0045] Furthermore, the first left arcuate edge 28 and the first right arcuate edge 38 together define a substantially cylindrical first fitting end 46. At the opposite end, the two first notched edges 30, 40 form a first Y-shaped end 48 which then captures the bushing 42.

[0046] Furthermore, two circular beads are applied to the connection portion of the bushing 42 to the right shell 18 and to the connection portion of the bushing to the left shell 20. In this way, the bushing 42 is completely fixed to the sleeve 44 and the bushing extends transversely, wherein the bushing protrusions protruding from the two shells 18, 20 have substantially the same length.

[0047] Furthermore, it will be observed that the first assembly end 46 extends in the assembly direction E, with its generatrix extending parallel to this assembly direction. Since the two first shells 18 , 20 are essentially curved, the first Y-shaped end 48 extends in the receiving direction H, which is then inclined relative to the assembly direction E.

[0048] The axis A of the bushing 42 is thus itself inclined relative to the assembly direction E at an angle of less than 90°.

[0049] The cross section of the first assembly end 46 is [ Figure 1 ] The cross-sections of the first ends 12 of the longitudinal tubular members 10 shown are substantially the same.

[0050] More specifically, the cross-section of the inner cylindrical surface of the first fitting end 46 is the same as the outer cylindrical surface of the first end 12 , so that the first end 12 can be fitted into the first fitting end 46 within the functional gap.

[0051] [ Figure 2 ] Thus, the first end 12 is shown fitted into the sleeve 44. Additionally, the sleeve and the first end are then secured by means of a weld bead applied to the junction between the first end 12 and the first arcuate edge 28, 38 of the sleeve 44.

[0052] The first sleeve 44 has a length L1 , which will be described herein as short.

[0053] In this way, a first left-hand suspension arm 45 is obtained, having a first length B1 measured between the centre C of the wheel support 16 and the centre of the bushing 42 .

[0054] The right suspension arm is also created in the same manner. The right and left arms are not identical. Furthermore, at the base, the tubular member that forms the left arm differs from the tubular member that forms the right arm. In contrast, the right tubular member is symmetrical to the left tubular arm about the midplane.

[0055] Advantageously, the same sleeve 44 can be mounted at the end of the left tubular member 10 and at the end of the right tubular member (not shown). To this end, the sleeve 44 is then rotated 180° relative to its assembly axis E so as to be able to receive the end of the right tubular member.

[0056] Moreover, the left and right suspension arms thus produced are then both connected together by means of a crossbeam, not shown. The two opposite ends of the crossbeam are then welded to the tubular member in a T-shape upstream of the sleeve.

[0057] The two suspension arms are thus connected to one another in a rigid manner.It will then be observed that the sleeves 44 substantially diverge relative to one another.

[0058] Furthermore, the bushing 42 then makes it possible to pivotally connect the end of the suspension arm to the vehicle body.

[0059] It will also be observed that the diameter of the notch edges 30, 40 can be adjusted to receive bushings of different diameters. Thus, Silentbloc® corresponding to the diameter of the bushing is fitted to filter vibrations differently.

[0060] The advantage of the manufacturing method according to the present invention is that at least one second sleeve 44' is designed to have a length greater than [ Figure 4 ]、[ Figure 5 ]and[ Figure 6 ] shown in the first sleeve 44 is long and the at least one second sleeve is mounted in [ Figure 2 ] on the tubular member 10.

[0061] Reference will be made to Figure 3 ], which is consistent with [ Figure 2 ] Elements of the subject matter of the present invention that perform the same function have the same reference numerals followed by an apostrophe symbol: "'".

[0062] therefore,[ Figure 3 ] Specifically shown is a second sleeve 44' into which the second end 12' of the second tubular member 10' is fitted to form a second left-side suspension arm 45'.

[0063] Thus, the second sleeve 44 ′ is produced in a similar manner to the first sleeve 44 by cutting and stamping a metal plate and then welding. In contrast, the dimensions of the second sleeve are different. Specifically, the length L2 of the second sleeve is longer than the length L1 of the first sleeve 44 .

[0064] Furthermore, a second sleeve is mounted in the same manner at the end 12' of the second tubular member 10'.

[0065] Thus, a second left-hand suspension arm 45' is obtained having a second length B2 measured between the centre C' of the wheel support 16' and the centre of the bushing 42'. The second length B2 is longer than the first length B1.

[0066] The wheel support 16 ′ and therefore the wheel (not shown) are therefore further from the articulation axis of the second bushing 42 ′ than the first arm 45 .

[0067] Furthermore, the second right arm is produced in the same manner as the second left arm, and the second right arm and the second left arm are then also connected together by means of the crossbeam.

[0068] Thus, different torsion axle structures can be manufactured using a common pair of tubular members and sleeves of different lengths for producing shorter or longer suspension arms. These different sleeves are produced at favorable cost and are assembled on the common tubular member according to the type of motor vehicle being manufactured.

Claims

1. A method for manufacturing a torsion axle structure for a motor vehicle, the method comprising the following steps: - providing a pair of first arms (45) connected to each other, having a first length, and designed to connect two wheels and a body of a vehicle of a first type; - providing pairs of second arms (45') connected to each other, having a second length longer than said first length, said pairs of second arms being designed to connect two wheels and a body of a vehicle of a second type; It is characterized by providing: - a plurality of pairs of longitudinal tubular members (10, 10') of the same length, each of which has a first end (12, 12') opposite to a second end (14, 14'); - a pair of short sleeves (44) and a pair of long sleeves (44'); Furthermore, the short sleeves (44) are installed at the first ends (12) of the tubular members in the pair of tubular members to provide the pair of first arms (45), while the long sleeves (44') are installed at the first ends (12') of the tubular members in the other pair of tubular members to provide the pair of second arms (45').

2. The manufacturing method according to claim 1, wherein Each sleeve (44, 44') in the pair of sleeves includes a mounting end (46) and a Y-shaped end (48) opposite the mounting end for receiving a laterally extending bushing (42).

3. The manufacturing method according to claim 2, wherein: The mounting end (46) is substantially cylindrical.

4. The manufacturing method according to claim 3, wherein: The assembly end (46) is defined by a generatrix parallel to the assembly direction E, while the Y-shaped end (48) is inclined relative to the assembly direction.

5. The manufacturing method according to any one of claims 2 to 4, characterized in that Two shell members (18, 20) are provided, each having two opposing longitudinal edges (34, 36; 22, 24) and an arcuate edge (38; 28) opposite the notched edge (40; 30), and the two members (18, 20) are connected together by their two opposing edges (34, 36; 22, 24) to form each of the pair of sleeves.

6. The manufacturing method according to claim 5, wherein: The notch edges (30, 40) of the two pieces (20, 18) define a circular shape between a half circle and a three-quarter circle.

7. The manufacturing method according to any one of claims 1 to 6, characterized in that The sleeves (44, 44') are welded to the first ends (12, 12') of the tubular members (10, 10') to install the sleeves.

8. The manufacturing method according to any one of claims 1 to 7, wherein: A plurality of cross beams are provided for connecting together the arms (45, 45') in each of the pair of first arms and the pair of second arms.

9. The manufacturing method according to claim 8, wherein: The cross beam is welded to each of the pair of first arms (45) and the pair of second arms (45').

10. The manufacturing method according to any one of claims 1 to 9, characterized in that A wheel support (16, 16') is mounted at the second end (14, 14') of the tubular member in the pair of tubular members.

11. A motor vehicle torsion axle structure manufacturing kit, characterized in that: The motor vehicle torsion axle structure manufacturing kit includes: - a pair of longitudinal tubular members (10, 10') of the same length, the pair of longitudinal tubular members being designed to be connected to each other, the first end (12, 12') of each of these tubular members being opposite to the second end (14, 14'); - a pair of short sleeves (44) and a pair of long sleeves (44'), enabling the short sleeves (44) to be mounted at the first ends (12) of the tubular members and providing a pair of first arms (45) connected together, or enabling the long sleeves (44') to be mounted at the first ends (12') of the tubular members and providing a pair of second arms (45') connected together.

12. A torsion axle structure for a motor vehicle, comprising: - a pair of first arms (45) connected to each other and having a first length, the pair of first arms being designed to connect two wheels and a body of a first vehicle; or, - a pair of second arms (45') connected to each other, having a second length longer than the first length, the pair of second arms being designed to connect two wheels and the body of the second vehicle; Characterized in that the motor vehicle torsion axle structure comprises a pair of longitudinal tubular members (10, 10') of the same length, wherein a first end (12, 12') of each of the tubular members is opposite to a second end (14, 14'); and - a pair of short sleeves (44) mounted at the first ends (12) of the tubular members of the pair of tubular members so as to form the pair of first arms (45); or, - A pair of long sleeves (44') mounted at the first ends (12') of the tubular members of the pair of tubular members to form the pair of second arms (45').

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