Independent Front Suspension Module Maximizing Wheel Cut
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Solution Overview
Problem
Existing independent front suspension (IFS) systems face challenges in maximizing wheel cut, simplifying installation, and providing variable load-carrying and ride height capabilities while minimizing strut and air spring loading.
Innovation Solution
The IFS assembly incorporates a single lower control arm with laterally-spaced ends, a strut with relative movement along its axis, and a steering knuckle that rotates freely below the air spring seat, allowing unconfined movement and maximizing wheel cut. This design includes a lower air spring seat supported by the control arm, an air spring engaging the chassis, and a strut with upper and lower ends that pivotally secure to the chassis and control arm, respectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the steering knuckle is positioned close to the air spring seat for compact design, then device complexity is reduced, but the available wheel cut is limited due to confined rotative movement
Solution Approach 1:
The air spring seat is positioned laterally offset from the strut axis rather than directly above it, creating additional lateral space. This dimensional rearrangement allows the steering knuckle to rotate through a larger angle without colliding with the air spring seat, thereby maximizing wheel cut while maintaining a compact overall design.
2Productivity
If traditional IFS assemblies are used, then structural support is provided, but installation complexity and time are increased due to multiple separate components
Solution Approach 1:
The lower control arm and air spring seat are merged into a single integrated component, eliminating the need for separate installation steps for these parts. This consolidation reduces the total number of components that must be installed and positioned separately, thereby reducing installation time and complexity while maintaining all necessary structural and suspension functions.
Solution Approach 2:
The integrated lower control arm and air spring seat assembly performs multiple functions simultaneously: it provides structural support, houses the air spring mounting, and enables suspension movement. This multi-functionality reduces the number of separate components needed, simplifying both the installation process and the overall system architecture.
3Force
If higher load-carrying capacity is required, then stronger struts and air springs are used, but the loading on these components increases beyond optimal levels
Solution Approach 1:
The lateral offset of the air spring seat from the strut axis changes the geometric relationship and load distribution in the suspension system. This parameter change allows for optimized load paths that reduce excessive loading on the struts and air springs while maintaining adequate load-carrying capacity, preventing over-stressing of these components.
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 configuration maximizes available wheel cut, simplifies installation, and provides adjustable load-carrying and ride height capabilities by reducing the loading on struts and air springs, enhancing the overall performance and flexibility of the IFS system.
Implementation Method 1
A lower air spring seat is supported by the lower control arm, the lower air spring seat adapted to upwardly support the chassis support structure relative to the lower control arm through an air spring engaging the chassis support structure
Data Source
AI summary
An IFS assembly having a single lower control arm having an inboard end pivotally secured to a chassis support structure, an air spring supported by an air spring seat relative to the lower control arm, a strut having an upper end pivotally secured to the chassis support structure and a lower end coupled to the lower control arm outboard end, and a steering knuckle fixed to the strut lower end, the steering knuckle disposed below the lower air spring seat and whose rotative movement about the strut axis is unconfined by proximity between the steering knuckle and the lower air spring seat, whereby available wheel cut is maximized. Also an IFS module including right and left side IFS assemblies and adapted for installation into a vehicle.