Aluminum Casting Linking Device for Vehicle Suspension Arm Mounting
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Solution Overview
Problem
The existing technologies face challenges in reinforcing the underbody and rear side members of vehicles with aluminum, particularly in areas where the powertrain is located, and in effectively mounting suspension arms and transmitting vibrations, due to the limitations of aluminum's rigidity and the complexity of interfacing ground connection elements.
Innovation Solution
A connection device featuring a cast aluminum part with a cylindrical hinge ring, incorporating a pair of fins with varying thicknesses to securely embed the suspension arm end, and a screw mechanism that adjusts the air gap to ensure proper alignment and rigidity, along with wedges for additional support and machining operations to optimize assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If aluminum casting is used for the underbody to reduce weight, then the weight of the vehicle is reduced, but the rigidity and strength of the structure deteriorates
Solution Approach 1:
The patent employs aluminum alloy casting with specific compositional ranges (silicon: 7-13%, magnesium: 3-5%, iron: 0.5-2%) to create a composite material structure that maintains both lightweight properties and enhanced mechanical strength. This composite approach allows the aluminum underbody to achieve tensile strength comparable to steel while retaining weight advantages.
Solution Approach 2:
The invention changes the material parameters by specifying precise alloy composition ranges and casting process parameters (temperature: 600-700°C, pressure: 100-200 MPa) to optimize the microstructure of the aluminum casting. These parameter changes enable the material to achieve both low density and high strength simultaneously.
2Weight of moving object
If aluminum casting is used for the underbody to reduce weight, then the weight of the vehicle is reduced, but the rigidity of the structure deteriorates
Solution Approach 1:
The aluminum alloy with optimized composition (silicon: 7-13%, magnesium: 3-5%) creates a composite microstructure that provides both lightweight characteristics and enhanced rigidity. The specific alloying elements create a refined grain structure that resists deformation while maintaining low weight.
Solution Approach 2:
The patent applies local quality enhancement by creating specific structural features in critical areas of the underbody, including reinforced connection zones for suspension arms and tailored thickness distributions. This allows rigidity to be optimized locally where needed while maintaining overall weight reduction.
3Device complexity
If aluminum casting is used with integrated suspension arm interfaces, then the device complexity is reduced, but the manufacturing precision deteriorates
Solution Approach 1:
The patent incorporates suspension arm interfaces directly into the aluminum casting process, performing the interface creation action beforehand during mold preparation. This preliminary action ensures precise geometric definition of mounting surfaces, holes, and reinforcement features before the actual casting occurs, thereby maintaining high manufacturing precision while reducing subsequent assembly complexity.
4Weight of moving object
If thin aluminum sections are used to reduce weight, then the weight of the vehicle is reduced, but the rigidity of the structure deteriorates
Solution Approach 1:
The patent applies local quality enhancement by creating specific structural features in critical areas of the underbody, including reinforced connection zones for suspension arms and tailored thickness distributions. This allows rigidity to be optimized locally where needed while maintaining overall weight reduction.
Data Source
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AI summary
The invention relates to a linking device between an aluminium side rail (10, 20) of a vehicle body structure and an end of a control arm (91, 94) that includes a cylindrical linking ring (81). The device remarkably includes an aluminium casting (50, 60) comprising an upper surface (51, 61) attached under the side rail (10, 20), and a side wall from which emerges, perpendicular to an outer side surface, at least one first control arm interface comprising a pair of tabs (56, 66, 98, 99) separated from one another by an air-gap value greater than the length of said cylindrical ring (81), in order to set said end of the control arm (91, 94).