Lightweight support, balanced suspension system and commercial vehicle

Abstract

The invention belongs to the technical field of commercial vehicle chassis, and discloses a lightweight support, a balanced suspension system and a commercial vehicle. Wherein the connecting parts comprise an upper connecting part, a middle connecting part and a lower connecting part, the upper connecting part, the middle connecting part and the lower connecting part are integrally formed, the upper connecting part, the middle connecting part and the lower connecting part are gradually narrowed, the upper connecting part is connected with the frame, one side of the middle connecting part is connected with the belly wing, the other side of the middle connecting part is connected with the balance shaft assembly, and the lower connecting part is connected with the lower reaction rod; the problem that in the prior art, a support at the bottom of a commercial vehicle is heavy, and consequently the overall weight of the vehicle is heavy is solved.

Description

Technical Field

[0001] The present invention relates to the technical field of commercial vehicle chassis, and in particular to a lightweight bracket, a balanced suspension system and a commercial vehicle. Background Art

[0002] In the field of automotive engineering, the balancing suspension system plays a vital role. It is an indispensable core load-bearing and connection hub in the chassis architecture of the entire vehicle. The system is firmly installed on the chassis frame of the vehicle body and undertakes multiple key functions such as transmitting complex loads, buffering road impacts, maintaining vehicle body posture stability, and coordinating wheel movement. As a key structural component that connects the upper and lower parts of the balancing suspension system, the balancing suspension bracket shoulders an especially important mission. It is not only a direct connection point for the frame longitudinal beam or cross beam, but also a physical convergence and force flow transmission interface for various core suspension components such as leaf springs and reaction rods (or thrust rods). Through this precise connection, the bracket ensures the coordinated operation of the various components of the suspension system, effectively transmitting the interaction force between the wheels and the road to the vehicle body, while supporting the weight of the vehicle body. Its structural integrity and reliability directly determine the driving safety, handling stability and ride comfort of the entire vehicle.

[0003] However, precisely because of its central structural position and the complex, multi-directional loads it bears, the design of the balancing suspension bracket often requires extremely high structural strength and rigidity to cope with the tremendous stresses generated by the vehicle under various operating conditions (such as acceleration, braking, cornering, and bumps). This stringent requirement for structural robustness under extreme operating conditions has traditionally led to the bracket adopting more conservative and heavy designs, typically based on solid or thick-walled structures that are cast or forged as a whole. As a result, the balancing suspension bracket accounts for a significant proportion of the total weight of the entire suspension system, becoming a significant "weight contributor" in the system.

[0004] Currently, the global automotive industry is facing increasingly severe pressures on energy consumption and environmental protection, driving vehicle lightweighting to become one of the core strategic directions of industry development. As a component with a prominent weight share in the suspension system, the balanced suspension bracket naturally becomes the focus of lightweight engineering.

[0005] Therefore, scientific, systematic, and effective lightweighting of the balancing suspension bracket is no longer just a technical optimization option; it is a highly urgent and strategic necessity. This requires engineers to thoroughly understand the complex multi-physics coupled loads (including static, dynamic, impact, and fatigue) to which the bracket is subjected, as well as its functional boundaries. They must then apply advanced design concepts (such as topology optimization, morphology optimization, and dimensional optimization), explore the potential applications of high-performance lightweight materials (such as high-strength steel, aluminum alloys, and composites), and innovate manufacturing processes (such as precision casting, additive manufacturing, and hydroforming). The goal is to eliminate redundant materials, optimize the structural form, and achieve significant weight reduction while ensuring structural safety margins, fatigue life, and functional reliability, all while maintaining the rigid constraints of ensuring safety margins, fatigue life, and functional reliability. Only in this way can the significant contradiction between the current weight and the overall vehicle lightweighting goal be effectively resolved, laying a solid foundation for the development of a more efficient, environmentally friendly, and high-performance next-generation automotive chassis system. Lightweighting the balancing suspension bracket has become an important and pressing engineering challenge in achieving the strategic goal of vehicle lightweighting.

[0006] Through the force and weight analysis of various parts on the commercial vehicle chassis, it is found that the brackets on both sides of the frame, which account for a relatively heavy part in the balanced suspension system, need to be connected to multiple different structural parts at the same time, and need to withstand forces in different directions and forms. This leads to a relatively bulky design of the bracket. A cylindrical protrusion is formed on one side of the bracket. The above protrusion needs to install the upper and lower covers of the balancing shaft. The upper cover of the balancing shaft is connected to the leaf spring through a U-bolt. The metal protrusion occupies a large weight of the bracket. At the same time, in order to meet the structural strength required by the vehicle during driving and not be easily deformed, the bracket as a whole is a solid structure, which further increases the weight of the bracket, resulting in a relatively bulky chassis of the vehicle. Summary of the Invention

[0007] The purpose of the present invention is to provide a lightweight bracket, a balanced suspension system and a commercial vehicle, so as to solve the problem that the bracket at the bottom of the commercial vehicle is relatively bulky in the prior art, resulting in a heavy overall weight of the vehicle.

[0008] To achieve this object, the present invention adopts the following technical solution: The present invention provides a lightweight bracket, including an upper connecting part, a middle connecting part and a lower connecting part, the upper connecting part, the middle connecting part and the lower connecting part are integrally formed, the upper connecting part, the middle connecting part and the lower connecting part gradually narrow, the upper connecting part is connected to the frame, one side of the middle connecting part is connected to the ventral wing, and the other side is connected to the balance shaft assembly, and the lower connecting part is connected to the lower reaction rod.

[0009] Preferably, the lightweight bracket is in an inverted triangle shape as a whole.

[0010] Preferably, a first connecting plate and a second connecting plate are symmetrically provided on both sides of the upper connecting portion, a first bolt hole is provided on the first connecting plate, a second bolt hole is provided on the second connecting plate, an arc-shaped groove is formed between the first connecting plate and the second connecting plate, a first fastener is installed in the first bolt hole and the second bolt hole, the first fastener is connected to the side of the frame, the first bolt holes are provided in eight groups and distributed in a rectangular shape, and the second bolt holes are provided in eight groups and distributed in a rectangular shape.

[0011] Preferably, the middle connecting part includes a middle connecting plate, one side of the middle connecting plate protrudes to form a boss, a third bolt hole is opened on the boss, a second fastener is installed in the third bolt hole, the second fastener is connected to the ventral wing, a rib plate is connected to the lower side of the boss, the rib plate is perpendicular to the connecting plate, a groove is formed between the rib plate and the connecting plate, and a partition plate is installed in the groove.

[0012] Preferably, a fixed shaft is installed on the other side of the middle connecting plate, and a balancing shaft is sleeved on the fixed shaft. The farther the fixed shaft is from the middle connecting plate, the smaller the diameter of the fixed shaft is, and the interior of the fixed shaft is hollow.

[0013] Preferably, the lower connecting portion is formed with a concave area, a lower reaction rod is installed in the concave area, a fixing hole is provided at the edge of the concave area, a fixing pin is installed on the fixing hole through a third fastener, and one end of the lower reaction rod is passed through the fixing pin.

[0014] Preferably, the two groups of lower connecting parts are connected by a transverse pull plate, through holes are opened on both sides of the transverse pull plate, and fourth fasteners are installed in the through holes, and the fourth fasteners are connected to the lower connecting parts.

[0015] Preferably, the balancing shaft assembly includes an upper balancing component and a lower balancing component, and a contact surface is formed on a bulge of the upper balancing component, and the contact surface abuts against the leaf spring.

[0016] A balanced suspension system includes the lightweight bracket described above, which is installed on both sides of the vehicle frame. A balancing shaft assembly is installed on the lightweight bracket, and a leaf spring is installed on the side of the balancing shaft assembly. A U-bolt is screwed onto the balancing shaft assembly, and the U-bolt abuts against the leaf spring.

[0017] A commercial vehicle comprises the above-mentioned balancing suspension system. A frame is mounted on the bottom of the commercial vehicle, and the balancing suspension system is mounted on the frame.

[0018] Beneficial effects: The upper connecting part, the middle connecting part and the lower connecting part are gradually narrowed. Since the volume of the middle connecting part and the lower connecting part is gradually reduced after narrowing, the weight occupied by the middle connecting part and the lower connecting part will be lower, which will reduce the overall weight of the lightweight bracket, and ultimately reduce the overall weight of the balanced suspension system, which can ultimately reduce the overall weight of the commercial vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 is a schematic diagram of a balanced suspension system of the present invention;

[0020] Figure 2 This is a front view of the lightweight bracket of the present invention;

[0021] Figure 3 This is a schematic diagram of the back side of the lightweight bracket of the present invention;

[0022] Figure 4 This is a main diagram of the horizontally pulled plate of the present invention;

[0023] Figure 5 It is a main body diagram of the balance shaft assembly of the present invention.

[0024] In the figure: 1. Lightweight bracket; 11. Upper connecting part; 111. First connecting plate; 112. Second connecting plate; 113. First bolt hole; 114. Second bolt hole; 12. Middle connecting part; 121. Boss; 122. Third bolt hole; 123. Rib; 124. Partition plate; 125. Fixed shaft; 13. Lower connecting part; 131. Concave area; 2. Transverse pull plate; 3. Balance shaft assembly; 31. Balance upper part; 32. Balance lower part; 4. U-bolt; 5. Leaf spring; 6. Lower reaction rod bracket; 7. Spring bracket. DETAILED DESCRIPTION

[0025] The present invention will be further described in detail below with reference to the accompanying drawings and examples. It will be understood that the specific embodiments described herein are intended only to illustrate the present invention and are not intended to limit the present invention. It should also be noted that, for ease of description, the accompanying drawings only illustrate portions relevant to the present invention, not all structures.

[0026] In the description of the present invention, unless otherwise expressly specified or limited, the terms "connected," "connected," and "fixed" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integration; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal communication between two components or interaction between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention in specific circumstances.

[0027] In the present invention, unless otherwise expressly specified or limited, a first feature being "above" or "below" a second feature may include the first and second features being in direct contact, or may include the first and second features being in contact not directly but through another feature between them. Furthermore, a first feature being "above," "above," and "above" a second feature may include the first feature being directly above or obliquely above the second feature, or may simply mean that the first feature is higher in level than the second feature. A first feature being "below," "below," and "below" a second feature may include the first feature being directly below or obliquely below the second feature, or may simply mean that the first feature is lower in level than the second feature.

[0028] In the description of this embodiment, the terms "upper," "lower," "right," and other orientations or positional relationships are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely for ease of description and simplified operation. They do not indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on the present invention. Furthermore, the terms "first" and "second" are used solely for descriptive purposes and have no special meanings.

[0029] The balancing suspension system is a key component of the vehicle chassis, connecting the vehicle body and supporting related suspension components. As a crucial component of this system, the balancing suspension bracket fulfills the core task of connecting the frame to the leaf springs and other connecting rod elements. Its structural strength directly impacts the stability and driving performance of the entire vehicle. However, the weight of this bracket accounts for a significant proportion of the entire suspension system, which is in stark contrast to the current automotive industry's increasing emphasis on vehicle lightweighting.

[0030] The main source of this weight lies in the design challenges of the bracket itself. In order to meet complex connection requirements, the bracket must simultaneously withstand loads from multiple connection points in different directions and forms. This multi-directional force characteristic forces the bracket structure to be conservative and heavy in design to ensure sufficient rigidity and strength to resist deformation or failure under the harsh conditions of vehicle driving (such as bumps, steering, and braking). It is particularly noteworthy that the bracket usually contains specific protrusion structures. These protrusions are used to install balance shaft-related components. They are usually made of metal as a whole, and in order to ensure the strength and durability of key connection points, the bracket body often adopts a solid or nearly solid structure. This design concept with strength and safety as the primary goal, although it ensures functional reliability, inevitably leads to a significant increase in the weight of the bracket itself and the chassis area where it is located, becoming a major obstacle to weight reduction of the entire vehicle.

[0031] Therefore, with vehicle lightweighting becoming an inevitable industry trend, scientific and effective lightweight design of balanced suspension brackets is particularly important and urgent. This requires a deep understanding of their complex stress states and functional requirements, and the exploration of innovative structural designs, material applications, or manufacturing processes. This aims to minimize redundant weight while ensuring the absolute reliability of their key performance (such as strength, stiffness, and fatigue life), thereby making a substantial contribution to reducing vehicle curb weight and improving fuel economy or range.

[0032] like Figures 1 to 5 As shown, in order to solve the above problems, the present invention provides a lightweight bracket 1, which includes an upper connecting portion 11, a middle connecting portion 12 and a lower connecting portion 13. The upper connecting portion 11, the middle connecting portion 12 and the lower connecting portion 13 are integrally formed, and the upper connecting portion 11, the middle connecting portion 12 and the lower connecting portion 13 are gradually narrowed. The upper connecting portion 11 is connected to the frame, one side of the middle connecting portion 12 is connected to the ventral wing, and the other side is connected to the balance shaft assembly 3, and the lower connecting portion 13 is connected to the lower reaction rod.

[0033] The lightweight bracket 1 of the present invention usually needs to be connected to the frame at the position of the upper connecting part 11. In order to match the frames of different models and sizes, it is usually necessary to install the upper connecting part 11 at different positions of the frame. In this way, the volume of the upper connecting part 11 is required to be larger, so that it can adapt to frames of different models. The position of the middle connecting part 12 is usually connected to the ventral wing and the balance shaft assembly 3. The volume of the ventral wing and the balance shaft assembly 3 is much smaller than the volume of the frame, and the stress borne by the ventral wing and the balance shaft assembly 3 is also much smaller than the stress generated by the frame. In this way, the middle connecting part 12 can be connected to the ventral wing and the balance shaft assembly 3. The volume of the upper connecting part 12 is reduced compared to that of the upper connecting part 11, which can reduce the overall weight of the lightweight bracket 1, and the lower connecting part 13 is usually connected through the lower reaction rod. The stress borne by the lower connecting part 13 is minimized, and the volume of the lower connecting part 13 can be reduced to be smaller than the volume of the middle connecting part 12. Ultimately, the lightweight bracket 1 can maintain its original strength structure unchanged at the position subjected to greater stress, and reduce the strength structure of the lightweight bracket 1 at the position subjected to less stress, thereby reducing the weight of the lightweight bracket 1 and lowering the quality of the commercial vehicle.

[0034] The lightweight bracket 1 is in the shape of an inverted triangle as a whole. In order to make the structure of the lightweight bracket 1 more smooth and natural and facilitate subsequent one-piece molding and casting, the lightweight bracket 1 is in the shape of an inverted triangle as a whole, which can reduce the space occupied at the bottom of the vehicle and make the space integration at the bottom of the frame higher.

[0035] A first connecting plate 111 and a second connecting plate 112 are symmetrically arranged on either side of the upper connecting portion 11. First bolt holes 113 are defined in the first connecting plate 111, while second bolt holes 114 are defined in the second connecting plate 112. An arcuate groove is formed between the first connecting plate 111 and the second connecting plate 112. First fasteners are installed within the first and second bolt holes 113, 114, and the first fasteners are connected to the side surfaces of the vehicle frame. Eight groups of first bolt holes 113 are arranged in a rectangular pattern, while eight groups of second bolt holes 114 are arranged in a rectangular pattern. The distance between the first connecting plate 111 and the second connecting plate 112 is shortened, reducing the volume and, consequently, the weight of the lightweight bracket 1.

[0036] In order to adapt to different types of frames, the first bolt holes 113 are divided into two rows, each row has four groups, and the second bolt holes 114 are also divided into two rows, each row has four groups. In this way, different frames can be adapted according to different models, so that the lightweight bracket 1 of the present invention has lower weight and higher versatility, and can be connected to frames of different models.

[0037] The middle connecting part 12 includes a middle connecting plate, one side of which protrudes to form a boss 121, and a third bolt hole 122 is opened on the boss 121, and a second fastener is installed in the third bolt hole 122, and the second fastener is connected to the ventral wing. The extended boss 121 can be connected to the ventral wing to fix the ventral wing, so that more components can be fixed at the position of the middle connecting part 12, and a rib 123 is connected to the lower side of the boss 121. The rib 123 is perpendicular to the connecting plate, and a groove is formed between the rib 123 and the connecting plate, and a partition plate 124 is installed in the groove. In order to reduce the weight of the middle connecting part 12, the groove is overlapped by the rib 123 and the partition plate 124 on the lower side of the boss 121. The boss 121 is prevented from deforming under stress, thereby reducing the weight of the overall lightweight bracket 1 while ensuring the working strength of the boss 121.

[0038] A fixed shaft 125 is installed on the other side of the middle connecting plate, and a balancing shaft is sleeved on the fixed shaft 125. The farther the fixed shaft 125 is from the middle connecting plate, the smaller the diameter of the fixed shaft 125. The interior of the fixed shaft 125 is hollow, which can reduce the weight occupied by the entire fixed shaft 125. At the same time, the fixed shaft 125 is a variable cross-section structure. The smaller the diameter of the fixed shaft 125, the smaller the volume occupied, which can reduce the weight of the fixed shaft 125 and make the overall weight of the lightweight bracket 1 lower.

[0039] Lower connecting portion 13 is formed with a recessed area 131, within which a lower reaction rod is mounted. A fixing hole is provided at the edge of recessed area 131, into which a fixing pin is mounted via a third fastener. One end of the lower reaction rod is inserted into the fixing pin. The provision of recessed area 131 allows it to precisely accommodate the lower reaction rod. Furthermore, the presence of recessed area 131 reduces the weight of lower connecting portion 13 while leaving space for the lower reaction rod.

[0040] The two sets of lower connecting portions 13 are connected by a transverse plate 2. Through holes are formed on both sides of the transverse plate 2. Fourth fasteners are installed in the through holes and connected to the lower connecting portions 13. The provision of the transverse plate 2 further enhances the integration of the balanced suspension system and the stability of the structure, thereby reducing the material used in the lightweight bracket 1 and lowering its overall mass. The transverse plate 2 is typically also stamped from the leaf spring 5, which reduces material sourcing and improves safety.

[0041] The balancing shaft assembly 3 includes a balancing upper component 31 and a balancing lower component 32. A contact surface is formed on the balancing upper component 31, and the contact surface abuts against the leaf spring 5. By increasing the contact surface with the leaf spring 5, the connection relationship between the balancing shaft assembly 3 and the leaf spring 5 can be made more stable, so that the lightweight bracket 1 can remain stable while reducing its weight.

[0042] A lightweight bracket 1 is mounted on either side of the vehicle frame. A balance shaft assembly 3 is mounted on the bracket 1. A leaf spring 5 is attached to the side of the balance shaft assembly 3. U-bolts 4 are screwed onto the balance shaft assembly 3 and abut against the leaf spring 5. These components constitute the balanced suspension system, which is mounted on the bottom of the vehicle. The spring bracket 7 and lower reaction rod bracket 6 of the balanced suspension system are lightweight, reducing overall weight.

[0043] Obviously, the above embodiments of the present invention are merely examples for the purpose of clearly illustrating the present invention and are not intended to limit the embodiments of the present invention. A person skilled in the art would be able to make various obvious changes, readjustments, and substitutions without departing from the scope of protection of the present invention. It is not necessary and impossible to enumerate all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the claims of the present invention.

Claims

1. A lightweight bracket, characterized in that: The vehicle comprises an upper connecting portion (11), a middle connecting portion (12) and a lower connecting portion (13), wherein the upper connecting portion (11), the middle connecting portion (12) and the lower connecting portion (13) are integrally formed, and the upper connecting portion (11), the middle connecting portion (12) and the lower connecting portion (13) are gradually narrowed. The upper connecting portion (11) is connected to the vehicle frame, one side of the middle connecting portion (12) is connected to the ventral wing, and the other side is connected to the balance shaft assembly (3), and the lower connecting portion (13) is connected to the lower reaction rod.

2. The lightweight bracket according to claim 1, characterized in that: The lightweight bracket (1) is in an inverted triangle shape as a whole.

3. The lightweight bracket according to claim 1, characterized in that: A first connecting plate (111) and a second connecting plate (112) are symmetrically arranged on both sides of the upper connecting portion (11); a first bolt hole (113) is provided on the first connecting plate (111); a second bolt hole (114) is provided on the second connecting plate (112); an arc-shaped groove is formed between the first connecting plate (111) and the second connecting plate (112); a first fastener is installed in the first bolt hole (113) and the second bolt hole (114); the first fastener is connected to the side surface of the vehicle frame; the first bolt holes (113) are provided in eight groups and are distributed in a rectangular shape; the second bolt holes (114) are provided in eight groups and are distributed in a rectangular shape.

4. The lightweight bracket according to claim 1, characterized in that: The middle connecting portion (12) includes a middle connecting plate, one side of the middle connecting plate protrudes to form a boss (121), a third bolt hole (122) is opened on the boss (121), a second fastener is installed in the third bolt hole (122), the second fastener is connected to the ventral wing, a rib (123) is connected to the lower side of the boss (121), the rib (123) is perpendicular to the connecting plate, a groove is formed between the rib (123) and the connecting plate, and a partition plate (124) is installed in the groove.

5. The lightweight bracket according to claim 4, characterized in that: A fixed shaft (125) is installed on the other side of the middle connecting plate. A balancing shaft is sleeved on the fixed shaft (125). The farther the fixed shaft (125) is from the middle connecting plate, the smaller the diameter of the fixed shaft (125). The interior of the fixed shaft (125) is in a hollow state.

6. The lightweight bracket according to claim 1, characterized in that: The lower connecting portion (13) is formed with an inner concave area (131), a lower reaction rod is installed in the inner concave area (131), a fixing hole is provided at the edge of the inner concave area (131), a fixing pin is installed on the fixing hole through a third fastener, and one end of the lower reaction rod is inserted into the fixing pin.

7. The lightweight bracket according to claim 1, characterized in that: The two groups of lower connecting parts (13) are connected via a transverse pull plate (2). Through holes are provided on both sides of the transverse pull plate (2). Fourth fasteners are installed in the through holes. The fourth fasteners are connected to the lower connecting parts (13).

8. The lightweight bracket according to claim 1, characterized in that: The balancing shaft assembly (3) comprises a balancing upper component (31) and a balancing lower component (32); a contact surface is formed on the balancing upper component (31), and the contact surface abuts against the leaf spring (5).

9. A balanced suspension system, characterized in that: The lightweight bracket (1) comprises the lightweight bracket (1) as claimed in claim 1, wherein the lightweight bracket (1) is installed on both sides of the vehicle frame, a balancing shaft assembly (3) is installed on the lightweight bracket (1), a leaf spring (5) is installed on the side of the balancing shaft assembly (3), a U-bolt (4) is screwed onto the balancing shaft assembly (3), and the U-bolt (4) abuts against the leaf spring (5).

10. A commercial vehicle, characterized in that: The commercial vehicle comprises the balancing suspension system according to claim 9, wherein a frame is mounted on the bottom of the commercial vehicle, and the balancing suspension system is mounted on the frame.

Images