Chassis Arm Damper Tab Integration

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Solution Overview

Problem

The existing methods for producing chassis arms with damper connection sections require additional, separately welded installation aids, which increase material and process costs and risk corrosion and quality inspection issues.

Innovation Solution

The chassis arm integrates a tab as an installation aid directly from the base material, eliminating the need for separate components and welding, thereby reducing costs and avoiding corrosion-prone gaps, with the tab serving as a support surface for the damper.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate damper stopper is welded to the chassis arm to provide a support surface for the damper, then the damper can be reliably mounted with proper preload, but additional material costs and significant welding process costs are incurred

Engineering Contradiction:

Improvereliable mounting of damperVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The installation aid is integrated directly into the chassis arm as a one-piece component during the stamping process, eliminating the need for separate welding operations. The support surface is formed as part of the chassis arm's base material, combining what were previously separate components into a single manufactured part.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The chassis arm's own base material is used to form the installation aid and support surface, eliminating the need for additional materials. The stamping process itself creates the necessary features without requiring separate welding materials or additional components.

Inventive Principle:

Principle #25Self-service

2Reliability

If a damper stopper is welded to the chassis arm to provide installation aid, then the support surface is attached to the bearing eye, but the additional element may loosen due to poor welding or corrosion

Engineering Contradiction:

Improveattachment reliabilityVSAvoidcorrosion risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The installation aid and support surface are merged with the chassis arm structure, forming a single corrosion-resistant unit. By eliminating the weld joint between separate components, the source of corrosion and loosening is removed entirely.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The potential harm of welding (corrosion, loosening) is converted into benefit by using the stamping process to form the installation aid directly from the chassis arm material, which is already protected by the base material's inherent corrosion resistance and existing protective coatings.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If separate welding is used to attach the installation aid, then the support surface is provided for the damper, but significant process costs and additional manufacturing steps are required

Engineering Contradiction:

Improvesupport surface provisionVSAvoidmanufacturing efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The installation aid and support surface are formed during the initial stamping process of the chassis arm, before any assembly operations. This preliminary formation of the support surface eliminates the need for subsequent welding operations and speeds up overall production.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The production of the chassis arm and the installation aid are merged into a single stamping operation. The support surface is created as part of the base material forming process, combining multiple manufacturing steps into one efficient operation.

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If an additional damper stopper component is used, then the installation aid function is provided, but material costs increase and waste is generated

Engineering Contradiction:

Improveinstallation aid functionVSAvoidmaterial waste

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The base material of the chassis arm serves multiple functions: it forms the structural chassis arm itself and simultaneously provides the installation aid with support surface. This multi-functionality eliminates the need for separate materials and reduces overall waste.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The chassis arm's base material serves itself by forming the installation aid features directly during stamping. The same material that creates the chassis arm structure also creates the support surface, eliminating the need for additional materials and reducing waste generation.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS10899185B2Chassis arm with damper connection section and method for production of a chassis arm

Publication Date: 2021.01.26 AUTOTECH ENGINEERING DEUTSCHLAND GMBH

AI summary

The invention relates to a chassis arm for a motor vehicle, having a first end section for connection to a chassis support, a second end section for connection at a wheel end, and a damper connection section exhibiting at least one bearing eye for connecting a damper. The bearing eye is assigned at least one installation aid with a support surface for the damper. The installation aid is formed integrally with the chassis arm, wherein the installation aid in the form of a tab is cut free from the base material of the chassis arm and converted to a body section of the chassis arm, and wherein at least a part of the tab is designed as a support surface for the damper. The invention also relates to a method for producing a chassis arm, in particular a spring control arm for a motor vehicle.