Front Sub-Frame Truss Structure for Rhombus Deformation Control

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Solution Overview

Problem

The rear portion of the front sub-frame with a trapezoidal shape in plan view is prone to deformation into a rhombus shape due to the limitations in thickness of the vertical brace, leading to reduced engine and lower arm support stiffness, which affects the operation responsiveness of the steering wheel.

Innovation Solution

A front sub-frame structure incorporating a cross member, tilt members, and a brace that forms truss structures by coupling the brace to intermediate portions of the tilt members, reducing vertical warpage and maintaining the trapezoidal shape, thereby enhancing the stiffness of the rear portion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a brace is added to reinforce the rear portion of the front sub-frame, then the stiffness of the rear portion is improved, but the brace cannot be made thick in the vertical direction to avoid interference with the engine, making it prone to warpage and deformation

Engineering Contradiction:
Improvestiffness of rear portionVSAvoidvertical thickness of brace
Core Design Contradiction:
StrengthVSShape

Solution Approach 1:

The patent transitions from a single vertical brace to a three-dimensional truss structure composed of multiple diagonal members arranged in a triangular configuration. This spatial arrangement in multiple dimensions provides enhanced stiffness and resistance to deformation without requiring individual members to be thick in the vertical direction, thus avoiding engine interference while maintaining structural integrity.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The reinforcement structure is divided into multiple discrete diagonal members (first and second diagonal members, third and fourth diagonal members) that form a truss assembly. Each member can be made thin to avoid engine interference, but their collective arrangement in a triangular truss configuration provides the necessary overall stiffness and prevents rhombus-shaped deformation of the rear portion.

Inventive Principle:
Principle #1Segmentation

2Stability of the object's composition

If the rear portion is reinforced with a thick brace, then the resistance to deformation is improved, but it interferes with the engine mounting space

Engineering Contradiction:
Improveresistance to deformationVSAvoidengine mounting space
Core Design Contradiction:
Stability of the object's compositionVSVolume of moving object

Solution Approach 1:

Instead of using a single thick vertical brace that would occupy vertical space and interfere with engine mounting, the patent employs a truss structure with diagonal members arranged in a three-dimensional configuration. This distributes the reinforcement function across multiple dimensions and orientations, providing high resistance to deformation while maintaining clear vertical clearance for engine installation.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The reinforcement function is segmented into multiple thin diagonal members rather than one thick member. Each member is positioned at specific angles and locations to optimize structural performance while minimizing interference with the engine compartment volume, allowing adequate space for engine mounting and maintenance access.

Inventive Principle:
Principle #1Segmentation

3Device complexity

If a simple brace structure is used, then the device complexity is reduced, but the trapezoidal shape deforms to a rhombus shape under load

Engineering Contradiction:
Improvestructure complexityVSAvoidtrapezoidal shape stability
Core Design Contradiction:
Device complexityVSShape

Solution Approach 1:

The rear portion reinforcement is segmented into multiple diagonal members (first diagonal member coupling left arm supporting part to right side member, second diagonal member coupling right arm supporting part to left side member, third and fourth diagonal members providing additional triangulation) arranged in a truss configuration. This segmentation creates multiple triangular units that collectively prevent rhombus-shaped deformation while maintaining a relatively simple overall structure that can be manufactured and assembled efficiently.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent introduces diagonal members that extend in oblique directions rather than purely vertical or horizontal orientations. This three-dimensional arrangement of members creates triangular truss units that provide superior resistance to shear and bending loads, preventing the trapezoidal shape from deforming into a rhombus under operational loads while keeping the structural design straightforward.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS10118643B2Front sub-frame structure
Publication Date: 2018.11.06 MAZDA MOTOR CORP
  • US10118643B2 patent drawing
  • US10118643B2 patent drawing
  • US10118643B2 patent drawing

AI summary

To reinforce a front sub-frame in such a manner that the front sub-frame having a trapezoidal shape formed by a cross member and left and right side members extending to one side is not deformed to a rhombus shape at the one side, a front sub-frame structure includes: a rear cross member (74) coupling arm supporting parts (71, 71) supported on left and right side members (6, 6); tilt members (75) coupling left and right intermediate portions of the rear cross member (74) to rear vehicle attachment parts (M3) of the side members (6); a brace (80) coupling the left and right arm supporting parts (71, 71) to the rear vehicle attachment parts (M3); and intermediate coupling parts (91) coupling the brace (80) to intermediate portions of the tilt members (75).