Arm Component with Underfill for Stress Distribution

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Solution Overview

Problem

Existing suspension arms suffer from concentrated stress at slits, impairing durability due to high torsional rigidity, necessitating a component that reduces torsional rigidity while maintaining durability.

Innovation Solution

A rod-shaped arm component with underfill parts formed to align the central axis with the load line, reducing torsional rigidity and distributing stress, and manufactured using a 3D printer to integrate cylindrical collar parts and hollow sections for optimal structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a slit is formed in the arm part to reduce torsional rigidity, then the torsional rigidity is reduced, but stress is concentrated on the slit which impairs durability

Engineering Contradiction:

Improvetorsional rigidityVSAvoiddurability

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The invention divides the internal structure of the arm component into multiple ribs (first ribs and second ribs) that are arranged in a segmented pattern around the central axis. This segmentation allows the structure to reduce torsional rigidity through the spaced arrangement while maintaining durability by distributing stress across multiple rib elements rather than concentrating it at a single slit location

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention employs asymmetric rib configurations where the first ribs and second ribs are positioned at different angular positions and may have different cross-sectional properties. This asymmetric arrangement optimizes the balance between torsional flexibility and stress distribution, preventing stress concentration while achieving the desired torsional rigidity reduction

Inventive Principle:

Principle #4Asymmetry

2Strength

If the arm component maintains high torsional rigidity for structural strength, then strength is improved, but durability is impaired due to stress concentration

Engineering Contradiction:

Improvestructural strengthVSAvoiddurability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The invention applies local quality by creating ribs with specific cross-sectional shapes and dimensions at specific locations within the arm component. Each rib is designed with optimized local properties (thickness, curvature, cross-sectional area) to provide structural strength in critical areas while allowing controlled flexibility in other regions, thereby maintaining overall strength without creating stress concentration points

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention transitions from a two-dimensional slit concept to a three-dimensional rib structure that extends radially from the central axis. This dimensional change allows the structure to provide strength through the volumetric distribution of rib material while the spaced arrangement of multiple ribs prevents stress concentration, achieving both strength and durability simultaneously

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentEP3524450B1Arm component and manufacturing method therefor

Publication Date: 2022.10.05 TOYOTA JIDOSHA KK

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AI summary

At least one underfill part is formed so that a central axis of the arm component coincides with a load line of the arm component. The central axis of the configuration is a line connecting centroids of cross-sectional shapes with one another in an axial direction of the arm component, the cross-sectional shapes being shapes on cross-sectional planes perpendicular to an axis of the arm component. The load line of the arm component is a line on which a load is imposed in the arm component.