Extruded Control Arm with Integral Bearings
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Solution Overview
Problem
Existing motor vehicle control arms are complex and costly to produce, with high dead weight and potential weak spots due to separate fabrication and joining of components, which complicates the production process and increases weight.
Innovation Solution
A motor vehicle control arm with an integral main body and integrally configured bearing receptacles, produced using an extruded profile with a cavity profile central portion and solid end portions, reducing weight and complexity while enhancing stability through a curved shape and band connection, allowing for dissimilar bearings and simplified production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If control arms are produced as welded two-piece components, then manufacturing flexibility is improved, but production complexity increases and potential weak spots are created at weld seams
Solution Approach 1:
The patent merges the control arm body and bearing receptacles into a single integrally formed component produced from an extruded profile. This eliminates the need for separate fabrication and welding of multiple parts, thereby reducing production complexity while maintaining manufacturing flexibility through the extrusion process.
2Ease of manufacture
If control arms are produced as cast components, then production cost is reduced, but dead weight increases and complex mechanical post-machining is required
Solution Approach 1:
The patent changes the manufacturing parameter from casting to extrusion. The extruded profile provides a lightweight structure with integrated bearing receptacles, eliminating the need for post-machining while reducing dead weight compared to cast components. The extrusion process allows precise geometric control without the material waste and heavy weight associated with casting.
3Ease of manufacture
If bearing receptacles are fabricated separately and coupled to end portions, then manufacturing flexibility is improved, but potential weak spots are created and weight increases
Solution Approach 1:
The patent merges the bearing receptacles with the end portions by forming them as integral parts of the extruded profile. This eliminates separate fabrication and coupling operations, thereby eliminating potential weak spots at connection interfaces while reducing overall weight by removing coupling elements such as screws, rivets, or weld seams.
4Stability of the object's composition
If control arms use solid material throughout, then structural stability is improved, but weight and material consumption increase
Solution Approach 1:
The patent applies local quality by varying the material distribution within the extruded profile. Solid material is concentrated at the end portions where bearing receptacles require high structural stability, while the central portion utilizes a cavity profile to reduce weight. This localized material allocation optimizes structural stability where needed while minimizing overall weight.
5Weight of moving object
If cavity profile is used in central portion, then weight is reduced, but structural stability may be compromised
Solution Approach 1:
The cavity profile is strategically placed only in the central portion of the control arm where lower structural stability is required. The end portions maintain solid material construction to provide the necessary stability for bearing receptacles. This local differentiation allows weight reduction in the central portion while preserving structural integrity at critical locations.
Data Source
AI summary
The disclosure relates to a motor vehicle control arm, like a wishbone, having an integral main body configured in a materially integral manner. A first bearing receptacle is connected to the main body. The main body has a first end portion having a second bearing receptacle, and a second end portion having a third bearing receptacle. The main body comprises a central portion. Said central portion connects the first and the second end portion. The central portion is configured as a cavity profile. The second and the third bearing receptacle are configured integrally and in a materially integral manner from the main body.