I-Beam Suspension Arm With Double-Thickness Flanges
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Solution Overview
Problem
Existing manufacturing processes for automotive suspension control arms struggle to achieve high stiffness and strength while minimizing weight, particularly in using sheet metal press-forming techniques, as they often result in suboptimal I-beam sections with equal flange and web thicknesses, leading to inefficient structural performance.
Innovation Solution
A suspension control arm is constructed from a single piece of sheet metal with a central web portion of single thickness and flange portions that are twice as thick, formed into an I-beam section with upstanding and downstanding closed sections, and welded to create a structurally superior I-beam configuration using MIG, TIG, ARC, or Laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sheet metal press-forming techniques are used to manufacture suspension control arms, then manufacturing complexity is reduced and production efficiency is improved, but the structural performance (stiffness and strength) deteriorates due to suboptimal I-beam sections with equal flange and web thicknesses
Solution Approach 1:
The patent applies local quality by creating non-uniform thickness distribution in the sheet metal control arm. The flange portions are formed with doubled thickness (2t) compared to the web portion (t), concentrating material where it is most needed for structural performance. This local variation in thickness allows the component to achieve optimal I-beam structural characteristics while maintaining the manufacturing advantages of sheet metal press-forming.
2Weight of moving object
If the weight of suspension control arms is reduced to minimize unsprung mass, then vehicle dynamics and handling are improved, but the strength and stiffness of the control arms deteriorate
Solution Approach 1:
The patent reduces overall weight while maintaining strength by implementing local quality variations in the sheet metal structure. The non-uniform thickness distribution (thinner web at t, thicker flanges at 2t) concentrates material strategically at the flanges where bending stresses are highest, allowing weight reduction in less critical areas while preserving structural integrity where it matters most.
Solution Approach 2:
The patent effectively creates a composite-like structure from single sheet metal by forming different thickness regions. The varying thickness profile (t and 2t regions) creates a heterogeneous structure that optimizes the strength-to-weight ratio, similar to how composite materials combine different properties in specific locations to achieve superior performance.
3Strength
If material is concentrated around the edges of the control arm structure to maximize in-plane second moment of area, then stiffness and strength are improved, but the weight of the control arm increases
Solution Approach 1:
The patent optimizes material distribution by concentrating thickness at the flange edges (2t) while maintaining thinner web sections (t). This local quality approach maximizes the second moment of area for in-plane stiffness by placing material at the extremities, while avoiding unnecessary weight increase in the central web region where material is less effective for resisting bending loads.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a lightweight yet highly stiff and strong suspension control arm with improved structural performance, effectively addressing the limitations of prior art by maintaining a favorable I-beam section with double-thickness flanges and single-thickness web, enhancing the vehicle's handling characteristics.
Implementation Method 1
The open ends of the sheet metal are adapted to terminate against the central web portion and be welded to the web portion using MIG, TIG, ARC or Laser welding or similar means.
Data Source
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AI summary
A structural element comprising a vehicle suspension control arm is constructed from a complex, single piece, sheet metal stamped component formed from a material of uniform thickness. The stamping is configured with the correct plan view shape and formed into an I-beam cross-section comprising a central web portion and two flange portions. The central web portion is configured as a single material thickness and the flange portions comprise upstanding and downstanding closed sections with a continuous double returned segment. The open ends of the sheet metal terminate at or near the central web portion and are welded to the web portion, and in an alternative embodiment also to the continuous double returned segment, to create a favorable structural I-beam section with flange portions twice the thickness of the web portion.