Method for manufacturing torsionally flexible axle structures

Abstract

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

Description

[0001] Title of the invention: Method for manufacturing twistable axle structures

[0002] [The present invention relates to a method of manufacturing twistable axle structures for a motor vehicle.

[0003] It is known to implement flexible axles at the rear of motor vehicles.

[0004] These axles consist of two parallel suspension arms connected to each other by a cross member. The two arms then have a front end mounted articulated on an anchor point on the vehicle body and a rear end equipped with a wheel support. The rear end of the suspension arms extends towards the rear of the vehicle, while the front end extends towards the front of the vehicle. And the wheel supports receive the rear wheels of the vehicle.

[0005] In addition, the suspension arms are also connected to the body by means of elastically compressible members, for example coil springs.

[0006] Different types of vehicles can be built on a common platform, from compact vehicles to larger and bulkier vehicles. Vehicles of these different types differ, for example, in their wheelbase, track (the distance between the wheels), and height.

[0007] Therefore, it is usual to provide on the same platform, on the one hand pairs of first arms connected to each other by a crosspiece and having a first length to be able to connect the two wheels and the body of a first type of vehicle; and on the other hand pairs of second arms connected to each other and having a second length greater than the first length, to connect the two wheels and the body of a second type of vehicle.

[0008] In other words, it is necessary to design and produce two different pairs of arms for the two types of vehicles manufactured on the common platform.

[0009] However, the design and production of these different types of arms is relatively expensive.

[0010] Also, a problem that arises and that the present invention aims to solve is to provide a method for manufacturing twistable axle structures that allows different types of axle structures to be installed on the same platform at more advantageous costs. For this purpose, a method for manufacturing twistable axle structures of a motor vehicle is proposed, comprising the following steps: pairs of first arms connected to each other of a first length adapted to connect the two wheels and the body of a first type of vehicle are provided; pairs of second arms connected to each other of a second length greater than said first length, adapted to connect the two wheels and the body of a second type of vehicle are provided.Also, there are provided: a plurality of pairs of longitudinal tubular members of the same length, each of the tubular members having a first end opposite a second end and pairs of short sleeves and pairs of long sleeves. And, the short sleeves are installed at the first ends of tubular members of pairs of tubular members, to provide said pairs of first arms, while the long sleeves are installed at the first ends of tubular members of other pairs of tubular members to provide said pairs of second arms.

[0011] Thus, a feature of the invention lies in the implementation of a common part of the arms, the tubular members, and sleeves of different lengths. The sleeves are then installed on the tubular members according to the required arm length, between the wheel support and the anchoring point on the vehicle body as will be explained below.

[0012] The sleeves are made of a metallic material, for example steel. This allows them to be easily connected to the tubular parts, which are themselves made of steel, by welding.

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

[0014] Thus, the tubular components and wheel supports are identical for the different vehicle types, and the different sleeves are installed depending on the vehicle type. In this way, the production of a substantial part of the different suspension arms is standardized, and therefore the manufacturing costs are reduced.

[0015] According to a particularly advantageous embodiment of the invention, each of the sleeves of said pairs of sleeves comprises a fitting end and, opposite, a Y-shaped end for receiving a sleeve extending transversely. Also, the Y-shaped end is oriented so as to be able to orient the sleeve transversely, in a substantially horizontal direction, while the first end of the tubular members is fitted into the fitting end. The sleeve, made of a metallic material, is then welded into the Y-shaped end of the sleeves. The sleeve is for example made of steel.

[0016] In addition to the length of the suspension arms, which is determined by the use of short or long bushings, a small-diameter bushing or a large-diameter bushing can also be attached to the bushings. This option allows the suspension arm to be connected to the body using silent blocks of different sizes, depending on the vibration damping requirements.

[0017] Also, and advantageously, said fitting end is substantially cylindrical. Correlatively, the first end of the tubular members is cylindrical, and the section of the fitting end and the first ends of the tubular members are identical. In this way, the first end of the tubular members and the fitting end of the sleeves cooperate perfectly with each other. This provides a better connection between the two.

[0018] According to a particularly advantageous embodiment of the invention, said fitting end is defined by generatrices parallel to a fitting direction, while said Y-shaped end is inclined relative to said fitting direction. Thus, the Y-shaped end has two branches, which are then inclined relative to the direction of the generatrices of the fitting end. Such an inclination makes it possible, to a certain extent, to reduce the track of the vehicle.

[0019] According to a preferred embodiment of the invention, two shell parts are provided, each having two opposite longitudinal edges and an arcuate edge opposite a notched edge, and said two parts are connected together respectively by their two opposite edges to form each of the sleeves of said pairs of sleeves. Such an embodiment makes it possible to produce sleeves using standard industrial cutting-stamping techniques, then welding. Parts are thus obtained at an advantageous cost.

[0020] Preferably, the notched edges of said two parts define a circular shape between a semicircle and three-quarters of a circle. The notched edges of the two parts extend opposite each other to form the Y-shaped end. And thanks to their shape, the socket can be easily connected to it. The socket has, for example, an external diameter substantially equal to the diameter of the notched edges of the two parts. And it is advantageously welded with the notched edges.

[0021] In other words, the sleeves are welded to the first ends of the tubular organs to install them.

[0022] Furthermore, a plurality of crosspieces are advantageously provided for connecting together the arms of each of said pairs of first and second arms. Preferably, the crosspieces are all identical and made of a metallic material. And the arms of each of the pairs of arms are connected by means of the tubular members upstream of the sleeves.

[0023] Advantageously, said T-shaped crosspieces are welded to each of said pairs of first and second arms.

[0024] Furthermore, preferably, wheel supports are installed at the second ends of the tubular members of said pairs of tubular members.

[0025] Other features and advantages of the invention will emerge from reading the description given below of particular embodiments of the invention, given for informational but non-limiting purposes, with reference to the appended drawings in which:

[0026] [Fig. 1] is a schematic side view of an element allowing the implementation of the method according to the invention;

[0027] [Fig. 2] is a schematic side view of the element shown in [Fig. 1] supplemented by another element in accordance with the invention;

[0028] [Fig. 3] is a schematic side view of the element shown in [Fig. 1] supplemented with yet another element in accordance with the invention;

[0029] [Fig. 4] is a detailed schematic exploded perspective view of said other element shown in [Fig. 2];

[0030] [Fig. 5] is a partial schematic top view of the object of [Fig. 4]; and, [Fig. 6] is a schematic top view of the object of [Fig. 4] after assembly.

[0031] [Fig. 1] shows a longitudinal tubular member 10 having a first end 12 opposite a second end 14. Also, the second end is equipped with a motor vehicle wheel support 16.

[0032] As will be explained in more detail below, this longitudinal tubular member 10, after being equipped and mounted, is inscribed in an orthogonal reference frame X, Y, Z, in which the X axis extends in a front-rear longitudinal direction of the motor vehicle, oriented towards the rear; the Y axis extends in a transverse direction of the vehicle, oriented from left to right; and the Z axis extends in a vertical direction, oriented away from the ground.

[0033] The longitudinal tubular member 10 is substantially curved so that the first end 12 extends in a first average direction D1 substantially inclined relative to a second average direction D2 of the second end 14, in the plane (X, Z).

[0034] Also, the first end 12 of the tubular member 10 is substantially deformed and ovalized by extending along the vertical component Z.

[0035] We will now refer to [Fig. 4], [Fig. 5] and [Fig. 6] before returning to [Fig.

[0036] 1] then on [Fig. 2],

[0037] [Fig. 4] shows a first right shell 18 extending opposite a first left shell 20. The first left shell 20 has two first opposite left longitudinal edges, an upper edge 22 and a lower edge 24, on the one hand, and an arcuate left edge 28, towards the rear, opposite a notched left edge 30, towards the front, on the other hand.

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

[0039] Conversely, the right shell 18 has two first opposite right longitudinal edges, a right upper edge 34 and a right lower edge 36. It also has an arcuate right edge 38, towards the rear, opposite a notched right edge 40 oriented towards the front and receiving a socket 42.

[0040] The notched right edge 40 defines a right circular shape identical to the left circular shape 32 and having the same radius R.

[0041] The sleeve 42 has an external radius close to the radius R of the notched edge 40 so that it can be engaged through and, as will be explained below, also through the left notched edge 30.

[0042] [Fig. 5] illustrates, seen from above, the object of [Fig. 4] and we thus find there, the right shell 18 opposite the left shell 20. Also, we will observe that the two shells 18, 20, are substantially curved, the right shell 18 is substantially concave, while the left shell 20 is parallel substantially convex. We also find on this [Fig. 5] the sleeve 42 engaged inside the notched right edge 40. Thus, the two shells 18, 20 are paired in such a way that the first lower left edge 24 comes to bear against the first lower right edge 36, and that the first upper left edge 22 comes to bear against the first upper right edge 34, while the sleeve 42 also extends through the notched left edge 30.

[0043] A weld bead is then applied to the joint of the first two upper edges 22, 34 and to the joint of the first two lower edges 24, 36 to secure them to each other and form a first sleeve 44 then appearing in [Fig. 6],

[0044] Also, the first arcuate left edge 28 and the first arcuate right edge 38 together delimit a first substantially cylindrical fitting end 46. Conversely, the first two notched edges 30, 40 form a first Y-shaped end 48 which then traps the sleeve 42.

[0045] Also, two circular weld beads are applied to the joint of the sleeve 42 and the right shell 18 and the left shell 20 respectively. In this way, the sleeve 42 is completely integral with the sleeve 44 and it extends transversely projecting from the two shells 18, 20 of substantially the same length.

[0046] Furthermore, it will be observed that the first fitting end 46 extends in a fitting direction E to which the generatrices of this end extend parallel. The two first shells 18, 20 being substantially curved, the first Y-shaped end 48 extends in a receiving direction H, then inclined relative to the fitting direction E.

[0047] Therefore, the axis A of the sleeve 42 is itself inclined in the fitting direction E by an angle of less than 90°.

[0048] The first fitting end 46 has a cross section substantially identical to the cross section of the first end 12 of the longitudinal tubular member 10 shown in [Fig. 1],

[0049] More precisely, the internal cylindrical surface of the first fitting end 46 has a section identical to the external cylindrical surface of the first end 12 so as to be able, apart from the functional clearance, to fit the first end 12 inside the first fitting end 46. Thus, in [Fig. 2] we find the first end 12 fitted into the sleeve 44. And they are then secured by means of a weld bead applied to the joint between the first end 12 and the first arcuate edges 28, 38 of the sleeve 44.

[0050] The first sleeve 44 has a length L1, which will be described here as short.

[0051] In this way, a first left suspension arm 45 is obtained having a first length B1 measured between the center C of the wheel support 16 and the center of the bushing 42.

[0052] Also, a right suspension arm is made in the same way. The right arm and the left arm are not completely identical. Also, basically the tubular organ intended to make the left arm is not identical to the tubular organ intended to make the right arm. On the other hand, the right tubular organ is symmetrical to the left tubular arm in relation to a median plane.

[0053] Advantageously, the same sleeve 44 can be installed at the end of the left tubular member 10 and at the end of a right tubular member, not shown. To do this, the sleeve 44 is then turned 180° relative to its fitting axis E to be able to receive the end of the right tubular member.

[0054] Also, the two suspension arms, left and right, are then connected together by means of a cross member (not shown). The two opposite ends of the cross member are then welded in a T-shape to the tubular members respectively, upstream of the sleeves.

[0055] Thus, the two suspension arms are rigidly connected to each other. It will then be observed that the sleeves 44 diverge significantly from each other.

[0056] Also, the 42 bushings then allow the end of the suspension arms to be pivotally connected to the body.

[0057] It will also be observed that the diameter of the notched edges 30, 40 can be adjusted to accommodate a bushing of a different diameter. Thus, a silentbloc® corresponding to the diameter of the bushing is adjusted to filter the vibrations differently.

[0058] The advantage of the manufacturing method according to the invention is to design at least one second sleeve 44' of a length greater than that of the first sleeve 44 shown in [Fig. 4], [Fig. 5] and [Fig. 6] and installed on the tubular member 10 of [Fig. 2],

[0059] We will refer to [Fig. 3] in which the elements playing the same role as those of the object of [Fig. 2] have the same reference accompanied by a prime sign: “ '”. Thus, [Fig. 3] shows precisely the second sleeve 44' in which a second end 12' of a second tubular member 10' is fitted to form a second left suspension arm 45'.

[0060] Thus, the second sleeve 44' is produced in a similar manner to the first sleeve 44, by cutting-stamping a metal plate, then welding. On the other hand, its dimensions are different. Indeed, it has a length L2, greater than the length L1 of the first sleeve 44.

[0061] Also, it is installed at the 12' end of the second 10' tubular member in the same way.

[0062] As a result, a second left suspension arm 45' is obtained having a second length B2 measured between the center C' of the wheel support 16' and the center of the bushing 42'. The second length B2 is greater than the first length B1.

[0063] Consequently, the wheel support 16', and therefore the wheel, not shown, is further from the articulation axis of the second bushing 42' than it is with the first arm 45.

[0064] Also, a second right arm is made in the same way as the second left arm and they are then connected together by means of a crosspiece as well.

[0065] Thus, different torsion axle structures are manufactured with pairs of common tubular members and sleeves of different lengths to create suspension arms of varying lengths. These different sleeves are produced at low cost and are fitted to common tubular members depending on the types of motor vehicles manufactured.

Claims

CLAIMS

1. [A method of manufacturing twistable axle structures for a motor vehicle comprising the following steps: - pairs of first arms (45) connected to each other of a first length adapted to connect the two wheels and the body of a first type of vehicle are provided; - pairs of second arms (45') connected to each other of a second length greater than said first length are provided, adapted to connect the two wheels and the body of a second type of vehicle; characterized in that: - a plurality of pairs of longitudinal tubular members (10, 10') of the same length, each of the tubular members having a first end (12, 12') opposite a second end (14, 14'); - pairs of short sleeves (44) and pairs of long sleeves (44'); and in that the short sleeves (44) are installed at the first ends (12) of tubular members of pairs of tubular members, to provide said pairs of first arms (45), while the long sleeves (44') are installed at the first ends (12') of tubular members of other pairs of tubular members to provide said pairs of second arms (45').

2. Manufacturing method according to claim 1, characterized in that each of the sleeves (44, 44') of said pairs of sleeves comprises a fitting end (46) and opposite, a Y-shaped end (48) for receiving a socket (42) extending transversely.

3. Manufacturing method according to claim 2, characterized in that said fitting end (46) is substantially cylindrical.

4. Manufacturing method according to claim 3, characterized in that said fitting end (46) is defined by generatrices parallel to a fitting direction E, while said Y-shaped end (48) is inclined relative to said fitting direction.

5. Manufacturing method according to any one of claims 2 to 4, characterized in that two shell pieces (18, 20) are provided, each having two opposite longitudinal edges (34, 36; 22, 24) and an edge in an arc (38; 28) opposite a notched edge (40; 30), and in that said two pieces (18, 20) are connected together respectively by their two opposite edges (34, 36; 22, 24) to form each of the sleeves of said pairs of sleeves.

6. Manufacturing method according to claim 5, characterized in that the notched edges (30, 40) of said two parts (20, 18) define a circular shape between a semicircle and three quarters of a circle.

7. 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 them.

8. A manufacturing method according to any one of claims 1 to 7, characterized in that a plurality of crosspieces are provided for connecting together the arms (45, 45') of each of said pairs of first and second arms.

9. Manufacturing method according to claim 8, characterized in that said crosspieces are welded to each of said pairs of first (45) and second (45') arms.

10. Manufacturing method according to any one of claims 1 to 9, characterized in that wheel supports (16, 16') are installed at the second ends (14, 14') of the tubular members of said pairs of tubular members.

11. Kit for manufacturing a twistable axle structure for a motor vehicle, characterized in that it comprises: - a pair of longitudinal tubular members (10, 10') of the same length adapted to be connected to each other, each of the tubular members having a first end (12, 12') opposite a second end (14, 14'); - a pair of short sleeves (44) and a pair of long sleeves (44') to be able to install the short sleeves (44) at the first ends (12) of the tubular members and provide pairs of first arms (45) connected together, or to be able to install the long sleeves (44') at the first ends (12') of the tubular members and provide pairs of second arms (45') connected together.

12. A twistable axle structure of a motor vehicle comprising: - a pair of first arms (45) connected together of a first length adapted to connect the two wheels and the body of a first vehicle; or, - a pair of second arms (45') connected together with a second length greater than said first length, adapted to connect the two wheels and the body of a second vehicle; characterized in that it comprises a pair of longitudinal tubular members (10, 10') of the same length, each of the tubular members having a first end (12, 12') opposite a second end (14, 14'); and, - a pair of short sleeves (44) installed at the first ends (12) of the tubular members of said pair of tubular members, to form said pairs of first arms (45); or, - a pair of long sleeves (44') installed at the first ends (12') of the tubular members of said pair of tubular members to form said pairs of second arms (45').

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