Unitary Cast Suspension Side Plates for Weight Reduction
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Solution Overview
Problem
Existing vehicle suspension systems face challenges in weight reduction, assembly complexity, and quality control due to weldment designs, which can lead to increased weight, assembly defects, and reduced design tolerance.
Innovation Solution
A suspension module with a subframe assembly featuring unitary, one-piece cast side plates that eliminate the need for welding, providing reduced weight, simplified assembly, and improved tolerance maintenance, along with specific features like control arm openings, differential mounting pads, and tie rod plug holes for secure component mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If weldment designs are used for suspension systems, then assembly flexibility is improved, but weight increases and assembly defects occur
Solution Approach 1:
The patent combines multiple separate weldment components into a single integrated suspension module cast in aluminum alloy. The side plates are cast as one-piece components with integrated control arm openings, differential mounting pads, and tie rod plug holes, eliminating the need for welding multiple parts together while maintaining assembly flexibility through the integrated design.
Solution Approach 2:
The patent changes the material parameter from steel weldment construction to aluminum alloy casting. This material substitution reduces weight while the casting process enables integration of multiple features into single components, achieving both weight reduction and assembly flexibility through the altered material and manufacturing approach.
2Strength
If weldment designs are used for suspension systems, then component connectivity is improved, but assembly complexity and quality control difficulties increase
Solution Approach 1:
The patent merges multiple connectivity functions into integrated casting features. The side plates include built-in control arm openings, differential mounting pads with pre-positioned holes, and tie rod plug holes, all cast as integral features rather than requiring separate welded connections. This reduces assembly complexity while maintaining structural connectivity.
Solution Approach 2:
The casting process performs preliminary action by creating precisely positioned mounting features, holes, and openings directly during manufacturing. The differential mounting pads are cast with pre-positioned holes at exact angular positions for drive pinion gear alignment, eliminating the need for complex assembly operations and quality control checks during final assembly.
3Strength
If weldment designs are used for suspension systems, then structural integrity is maintained, but design tolerance and manufacturing precision decrease
Solution Approach 1:
The patent changes the manufacturing process parameter from welding to precision casting. The aluminum alloy casting process produces side plates with tight tolerances and consistent dimensional accuracy, eliminating the variability and potential defects associated with welding operations. The integrated casting ensures uniform material properties and precise feature positioning throughout the structure.
Solution Approach 2:
By integrating multiple features into single cast components, the patent eliminates the interfaces and joints where tolerance accumulation occurs in weldment assemblies. The unified casting structure maintains consistent material properties and dimensional accuracy across the entire side plate, improving overall manufacturing precision and design tolerance.
Data Source
AI summary
A suspension module for a vehicle and a method of manufacture. The suspension module may include a subframe assembly having at least one unitary side plate that is configured to be mounted to a vehicle. The subframe assembly may facilitate mounting of an axle subassembly and a suspension subsystem to the vehicle.