Double-plate lightweight control arm

Abstract

The invention relates to the field of automobile control arms, in particular to a double-plate light-weight control arm which comprises an upper plate, a lower plate, an assembly type ball pin assembly arranged between the upper plate and the lower plate and two sets of lining assemblies, the upper plate and the lower plate are of a double-layer metal plate buckling welding structure, the structure is excellent in modal and buckling performance, and the assembly type ball pin assembly and the lining assemblies are arranged on the upper plate and the lower plate. Compared with a single-layer structure, the structure is obviously improved; the stress center is reinforced by adopting sleeve welding, so that the modality is improved, and the stability and the reliability of the structure are enhanced; the weight of a product is reduced by 0.357 kg through the optimized design of the lightening holes and the flanging reinforcing ribs, so that the product is lighter, the bearing capacity is enhanced, the welding consistency is ensured, and the fuel efficiency and the performance of a vehicle are better improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automobile control arms, and particularly relates to a double-plate lightweight control arm. BACKGROUND

[0002] As an important component of the automobile suspension system, the performance of the control arm directly affects the steering stability, driving safety and ride comfort of the automobile. The main functions of the control arm include: support and connection; control of wheel movement; maintenance of wheel positioning; transmission of power; improvement of safety; and improvement of comfort.

[0003] At present, the control arm is mostly made of a single-layer stamped steel plate structure. Due to the complex profile of the single-layer plate and the large number of processes, the key parts (such as the deep inner flange at the front sleeve and the round flange at the rear sleeve) have risks such as excessive thinning rate and hidden cracks during mass production. In order to achieve certain performance indicators, the single-layer plate structure needs to arrange deep protruding features in the cross-sectional direction to increase the cross-sectional area. The profile of the single-plate structure is usually complex and has a large number of processes. Due to the complex profile of the single-layer plate, the stamping forming process of the key parts such as the deep inner flange at the front sleeve and the round flange at the rear sleeve is difficult, and multiple processes are required. During subsequent mass production, there are risks such as excessive thinning rate and hidden cracks. The stamping springback control of the single-layer plate structure is difficult, which leads to poor consistency of the parts. The deformation of the single-layer plate due to tailor-welding causes stress concentration, resulting in poor welding consistency. In addition, the failure rate of the single-layer plate is higher than that of the double-plate structure. SUMMARY

[0004] To solve the above problems, the present application provides a double-plate lightweight control arm.

[0005] A double-plate lightweight control arm includes an upper plate and a lower plate, an assembled ball pin assembly arranged between the upper plate and the lower plate, and two groups of bushing assemblies. A sleeve is arranged on the bushing assembly. The upper plate and the lower plate are integrally formed by an integral forming process. A plurality of lightening holes are arranged on the low stress area of the upper plate and the lower plate. An integrally stamped flange reinforcing rib is arranged at the edge of the lightening hole.

[0006] Further, the sleeve, the upper plate and the lower plate are all welded.

[0007] Further, the upper plate and the lower plate are welded to form a closed cross section by carbon dioxide protection welding.

[0008] Further, the welding gap is controlled to be less than or equal to 0.1 mm by using a clamp, and the welding penetration is greater than or equal to 80% of the plate thickness.

[0009] The beneficial effects of the present application are: the upper plate and the lower plate of the present application adopt a double-layer sheet metal buckling welding structure, which has superior performance in modal and buckling type, and has significant improvement compared with a single-layer structure; the stress center is strengthened by sleeve welding, which improves the modal and enhances the stability and reliability of the structure; the product weight is reduced through the optimization design of the weight reduction hole and the flange reinforcing rib, which reduces 0.357 kg, makes the product more lightweight, at the same time enhances the bearing capacity, ensures the consistency of welding, and is more helpful to improve the fuel efficiency and performance of the vehicle. BRIEF DESCRIPTION OF DRAWINGS

[0010] The present application will be further described below in conjunction with the drawings and examples.

[0011] Figure 1 A single-layer plate control arm assembly for the background art of the present application is shown in the figure. Figure 2 A double-layer plate control arm assembly structure of the present application is shown in the figure. Figure 1 Figure 3 A single-layer plate control arm applying X-direction buckling load result diagram of the present application is shown in the figure. Figure 4 A single-layer plate control arm applying -X-direction buckling load result diagram of the present application is shown in the figure. Figure 5 A single-layer plate control arm applying Y-direction buckling load result diagram of the present application is shown in the figure. Figure 6 A single-layer plate control arm applying -Y-direction buckling load result diagram of the present application is shown in the figure. Figure 7 A double-layer plate control arm applying X-direction buckling load result diagram of the present application is shown in the figure. Figure 8 A double-layer plate control arm applying -X-direction buckling load result diagram of the present application is shown in the figure. Figure 9 A double-layer plate control arm applying Y-direction buckling load result diagram of the present application is shown in the figure. Figure 10 A double-layer plate control arm applying -Y-direction buckling load result diagram of the present application is shown in the figure. Figure 11 A weight reduction hole structure diagram of the present application is shown in the figure. Figure 12 A double-layer plate control arm assembly structure of the present application is shown in the figure. Figure 1 Figure 13 A flange reinforcing rib structure diagram of the present application is shown in the figure. REFERENCE NUMERALS: 1, upper plate; 2, lower plate; 3, assembled ball pin assembly; 4, bushing assembly; 5, sleeve; 6, weight reduction hole; 7, flange reinforcing rib.​​ DETAILED DESCRIPTION

[0012] In order to make the technical means, creative features, purposes and effects of the present application easy to understand, the present application is further described below.

[0013] As shown in Figures 2 to 13 A double-plate lightweight control arm, comprising an upper plate 1 and a lower plate 2, an assembled ball pin assembly 3 arranged between the upper plate 1 and the lower plate 2, and two sets of bushing assemblies 4. As shown in Figure 2 The bushing assembly 4 is provided with a sleeve 5, and the stress center is strengthened by welding the sleeve 5, which improves the modal and enhances the stability and reliability of the structure. As shown in Figure 2 The upper plate 1 and the lower plate 2 are both made by integral molding process, and the overall shape of the plate is designed in streamline shape, so that the overall stress of the geometric surface is uniform, which can reduce air resistance and avoid stress concentration. As shown in Figure 2 and Figure 11 A plurality of weight-reducing holes 6 are arranged on the low-stress area of the upper plate 1 and the lower plate 2, so that the product weight is reduced by optimization design, which reduces 0.357 kg, making the product more lightweight, which helps to improve the fuel efficiency and performance of the vehicle. As shown in Figure 13 The edge of the weight-reducing hole 6 is provided with an integrally stamped and formed flange reinforcing rib 7, and the buckling strength of the double-layer sheet metal product reaches 38.1 kn, which is 15.9 kn / kn higher than that of the single-layer sheet metal product of 22.2 kn, thereby enhancing the carrying capacity and durability of the product.

[0014] The sleeve 5, the upper plate 1 and the lower plate 2 are all welded and made of sheet metal, and the modal frequency of the double-layer sheet metal product reaches 591 Hz, which is significantly higher than that of the single-layer sheet metal product of 230-300 Hz, thereby improving the control stability and comfort of the vehicle.

[0015] As a specific embodiment of the present application, the materials of the upper plate 1 and the lower plate 2 are both QStE420, T=2.0 mm.

[0016] The upper plate 1 and the lower plate 2 are welded to form a closed section by carbon dioxide shielded welding, and the welding path avoids the high-stress area such as the inside of the sleeve, thereby preventing stress concentration and effectively ensuring the welding consistency. The double-layer sheet metal clamping and welding structure is adopted, which has superior performance in modal and buckling performance, and is significantly improved compared with the single-layer structure.

[0017] The welding process employs a fixture to control the welding gap to ≤0.1mm and the welding penetration depth to ≥80% of the plate thickness. The double-plate welding has good redundancy in penetration depth, further ensuring the consistency of the welding.

[0018] The height of the flanged reinforcing rib 7 is 1.5T, where T = plate thickness. This is done to minimize the weight of the control arm while ensuring its overall strength and rigidity.

[0019] The flange angle of the flanged reinforcing rib 7 is 30°±2°.

[0020] Figure 1 The single-layer plate control arm in the background technology, with reference numeral a representing the main plate and reference numeral b representing the secondary plate, requires deep protrusions in the cross-sectional direction to increase the cross-section in order to achieve the corresponding performance indicators. Single-layer plate structures are typically complex in shape and involve numerous processes. Due to the complexity of the single-layer plate shape, the stamping process for key parts such as the deep inner flange at the front sleeve and the round flange at the rear sleeve is difficult, requiring multiple processing steps. Subsequent mass production carries risks of excessive thinning rate and micro-cracks. Controlling the springback during stamping in single-layer plate structures is challenging, leading to poor component consistency. Furthermore, welding deformation causes stress concentration, resulting in poor welding consistency. In addition, the failure rate of single-layer plates is higher than that of double-layer plate structures.

[0021] Buckling analysis of single and double plate control arms with bushings was examined, considering buckling loads under ±X and ±Y conditions to mitigate subsequent buckling risks and ensure the structure meets design objectives. The numerical model is as follows:

[0022] Constrain the first 1-6 degrees of freedom on the front and rear bushing sides of the single-layer and double-layer arms respectively, constrain the outer control points, and apply forced displacements in the ±X and ±Y directions to the outer control points respectively.

[0023] like Figure 3 As shown, the single-layer plate front and rear bushing assemblies are constrained with 1-6 degrees of freedom on 4 sides, and the control point is constrained with 3 degrees of freedom outside. A forced displacement in the +X direction is applied to the control arm outside. As can be seen from the figure, when the displacement is 28, the structure deforms and permanently bends. At this time, the critical value of the maximum external force that the structure can withstand to maintain stability is 22129N.

[0024] like Figure 4 As shown, the first to sixth degrees of freedom of the single-layer plate front and rear bushing assemblies on four sides are constrained respectively, and the third degree of freedom outside the control point is constrained. A forced displacement in the -X direction is applied to the outer point of the control arm. As can be seen from the figure, when the displacement is 29, the structure deforms and permanently bends. At this time, the critical value of the maximum external force that the structure can withstand to maintain stability is 22234N.

[0025] like Figure 5As shown, the single-layer plate front and rear bushing assemblies are constrained for 1-6 degrees of freedom on 4 sides, and the control point is constrained for 3 degrees of freedom outside. A forced displacement in the +Y direction is applied at the control arm's outer point. As can be seen from the figure, when the displacement is 4.5, the structure deforms and undergoes permanent bending. At this point, the critical value of the maximum external force that the structure can withstand to maintain stability is 50960 N.

[0026] like Figure 6 As shown, the single-layer plate front and rear bushing assemblies are constrained with 1-6 degrees of freedom on 4 sides, and the control point is constrained with 3 degrees of freedom outside. A forced displacement in the -Y direction is applied to the control arm outside. As can be seen from the figure, when the displacement is 5.1, the structure deforms and permanently bends. At this time, the critical value of the maximum external force that the structure can withstand to maintain stability is 79078N.

[0027] like Figure 7 As shown, the first to sixth degrees of freedom on four sides of the double-layer plate front and rear bushing assemblies are constrained, and the third degree of freedom outside the control point is constrained. A forced displacement in the +X direction is applied at the control arm's outer point. The figure shows that when the displacement is 28°, the structure deforms and undergoes permanent bending. At this point, the critical value of the maximum external force that the structure can withstand to maintain stability is 24906 N.

[0028] like Figure 8 As shown, the first to sixth degrees of freedom on four sides of the double-layer plate front and rear bushing assemblies are constrained, and the third degree of freedom outside the control point is constrained. A forced displacement in the -X direction is applied at the control arm's outer point. The figure shows that when the displacement is 49°, the structure deforms and undergoes permanent bending. At this point, the critical value of the maximum external force that the structure can withstand to maintain stability is 38123 N.

[0029] like Figure 9 As shown, the first to sixth degrees of freedom on four sides of the double-layer plate front and rear bushing assemblies are constrained, and the third degree of freedom outside the control point is constrained. A forced displacement in the +Y direction is applied at the outer point of the control arm. As can be seen from the figure, when the displacement is 10, the structure deforms and undergoes permanent bending. At this point, the critical value of the maximum external force that the structure can withstand to maintain stability is 53974 N.

[0030] like Figure 10 As shown, the first to sixth degrees of freedom on four sides of the double-layer plate front and rear bushing assemblies are constrained, and the third degree of freedom outside the control point is constrained. A forced displacement in the -Y direction is applied at the outer point of the control arm. As can be seen from the figure, when the displacement is 13, the structure deforms and undergoes permanent bending. At this point, the critical value of the maximum external force that the structure can withstand to maintain stability is 100112N.

[0031] The analysis results are as follows:

[0032] The buckling load reflects the ability of the structure to resist buckling risk, the larger the load value, the stronger the buckling performance, the better the product performance, as the above table comparison can be known, the buckling load value of the single-layer plate under the working condition of forced displacement in ±X and ±Y directions is lower than that of the double-layer plate, which shows that the strength and buckling performance of the double-layer plate are qualified, and the performance of the single-layer plate is unqualified.

[0033] The above shows and describes the basic principles, main features and advantages of the present application. Those skilled in the art should understand that the present application is not limited to the above-mentioned embodiments, and the above-mentioned embodiments and descriptions in the specification are only the principles of the present application. Without departing from the spirit and scope of the present application, various changes and improvements can be made to the present application, and these changes and improvements all fall within the scope of the claimed present application. The scope of protection of the present application is defined by the appended claims and their equivalents.

Claims

1. A twin plate lightweight control arm, characterized by: It comprises an upper plate (1), a lower plate (2), an assembled ball pin assembly (3) arranged between the upper plate (1) and the lower plate (2), and two groups of bushing assemblies (4). The bushing assembly (4) is provided with a sleeve (5). The upper plate (1) and the lower plate (2) are both made by an integral forming process. The upper plate (1) and the lower plate (2) are provided with a plurality of groups of lightening holes (6) in the low stress area. The edge of the lightening hole (6) is provided with an integral stamping formed flange reinforcing rib.

2. The dual plate lightweight control arm of claim 1, wherein: The sleeve (5), the upper plate (1) and the lower plate (2) are all welded.

3. The dual plate lightweight control arm of claim 1, wherein: The material of the upper plate (1) and the lower plate (2) is QStE420, T=2.0mm.

4. The dual plate lightweight control arm of claim 1, wherein: The upper plate (1) and the lower plate (2) are welded by carbon dioxide protection welding to form a closed section.

5. The twin-web light-weight control arm of claim 4, wherein: The welding gap controlled by the clamp is ≤0.1mm, and the welding penetration is ≥80% of the plate thickness.

6. The dual plate light-weight control arm of claim 1, wherein: The height of the flange reinforcing rib (7) is 1.5T, where T is the plate thickness.

7. The dual plate light-weight control arm of claim 1, wherein: The flange angle of the flange reinforcing rib (7) is 30°±2°.

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