Asymmetrical Sheet Metal Suspension Arm Flange Design
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Solution Overview
Problem
Current suspension arms for automotive multi-link suspensions face challenges in balancing production costs, weight, and mechanical efficiency, with existing designs either being costly due to asymmetrical parts or mechanically inefficient due to symmetrical identical parts.
Innovation Solution
A method to create suspension arms by cutting and shaping sheet metal into asymmetrical parts with overlapping flanges, allowing for reduced weight and improved mechanical properties, while maintaining simplicity in tooling and manufacturing, and enabling the use of ball and socket or elastic joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two identical symmetrical parts are used to form the suspension arm, then production costs are reduced and manufacturing is simplified, but mechanical efficiency and stiffness are compromised
Solution Approach 1:
The patent applies asymmetry by designing two different parts (first part and second part) instead of using identical symmetrical parts. The first part has a first flange and the second part has a second flange with different configurations, allowing optimization of mechanical efficiency while maintaining manufacturability through standardized production processes for each part type.
Solution Approach 2:
The suspension arm is segmented into two separate parts that are joined together. This segmentation allows each part to be optimized independently for its specific functional requirements, with the first part containing a first opening and the second part containing a second opening, enabling tailored design for mechanical efficiency.
2Strength
If two different asymmetrical parts are used to form the suspension arm, then mechanical efficiency is improved, but production costs increase and manufacturing complexity increases
Solution Approach 1:
The patent uses copying by creating two parts that are substantially identical in their overall structure and manufacturing process, even though they have different flange configurations. This allows for standardized production methods to be applied to both parts, reducing manufacturing complexity and cost despite the asymmetry in the final assembly.
Solution Approach 2:
Both parts share universal characteristics in terms of their base structure, material composition, and manufacturing process. The first part and second part are both formed from sheet material through similar stamping or forming operations, allowing for efficient production while accommodating the specific functional requirements of each part through their respective flange designs.
3Ease of manufacture
If traditional sheet stamping with symmetrical parts is used, then manufacturing is simple, but weight and mechanical properties are suboptimal
Solution Approach 1:
The patent applies local quality by giving different local characteristics to different parts of the suspension arm. The first flange and second flange have different configurations optimized for their specific locations and loading conditions, allowing weight reduction in non-critical areas while maintaining strength where required, rather than using a uniform symmetrical design throughout.
Data Source
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AI summary
The present invention relates to a method for obtaining a suspension arm for automotive vehicles which comprises obtaining two identical parts (1) to form a body, where each part (1) is obtained by means of: a) cutting a metal or composite sheet forming a base plane, such that a central segment (2) and two ends (3) are defined, b) drawing at least one hole (4) in each end (3), c) stamping each part (1) forming in its central segment (2) two flanges (5, 6) consisting of a first flange (5) and a second flange (6) located on opposite sides of the central segment (2) and oriented perpendicular to the base plane, where said flanges (5, 6) have an asymmetrical arrangement with respect to a midplane passing through the geometric centers of the holes (4) of the two ends (3) and is perpendicular to the base plane, the second flange (6) being separated from the midplane a distance equal to the separation of the first flange (5) from the midplane plus a distance at least equal to the value of the thickness of the sheet or plate.