Integrated Axle Support for Multi-Link Suspension
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Solution Overview
Problem
Current axle supports for multi-link vehicle suspensions face challenges in versatility, corrosion resistance, manufacturing complexity, cost-effectiveness, weight reduction, and improved driving dynamics, comfort, and acoustic properties, while also requiring easier assembly, maintenance, and increased load capacity with reduced installation space and noise damping.
Innovation Solution
A multi-link suspension axle support design featuring two longitudinal members connected by cross members, with integrated drive motor housings cast as one-piece components, utilizing lightweight materials and optimized geometries for reduced weight and increased load capacity, and incorporating various attachment methods such as gluing, welding, and clinching to minimize parts and weld seams, while providing recesses for chassis components and noise damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional multi-part axle supports with separate weld seams are used, then manufacturing flexibility is maintained, but weight is higher and structural rigidity is reduced
Solution Approach 1:
The patent combines multiple separate components (longitudinal members, cross members, and drive motor housings) into a single integrated cast axle support structure. This merging eliminates the need for separate parts and weld seams, directly reducing weight while maintaining manufacturing feasibility through casting processes.
Solution Approach 2:
The patent employs composite material construction by integrating different functional elements (structural support members and drive motor housings) into a unified cast component. This allows optimization of material distribution within the single piece, reducing overall weight while preserving structural integrity and rigidity.
2Stability of the object's composition
If multiple separate components are assembled together, then ease of manufacturing individual parts is maintained, but the number of weld seams increases and structural rigidity decreases
Solution Approach 1:
The patent merges the longitudinal members, cross members, and drive motor housings into a single monolithic cast structure. This eliminates all weld seams and joints between these components, significantly improving structural rigidity and stability while the casting process itself handles the manufacturing complexity.
3Adaptability or versatility
If conventional axle support designs are used, then basic functionality is maintained, but versatility for different drive configurations is limited
Solution Approach 1:
The patent designs the integrated axle support with universal adaptability by incorporating multiple receiving provisions that can accommodate different drive motor configurations (e.g., in-wheel motors, hub motors). The single-piece design with integrated mounting points allows the same structure to serve multiple drive arrangements, enhancing versatility without requiring separate design variants.
4Reliability
If traditional separate component designs are used, then ease of replacement for maintenance is maintained, but corrosion resistance at connection points deteriorates
Solution Approach 1:
The patent combines all structural members into a single corrosion-resistant cast unit, eliminating weld seams and connection points where corrosion typically initiates. The unified structure ensures consistent protective coating application and eliminates galvanic corrosion risks between dissimilar metals, significantly improving corrosion resistance while maintaining reliability.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
The invention relates to a crossmember, in particular the rear crossmember of a motor vehicle, for a multi-link suspension of the wheel, characterised in that the crossmember has a respective receiving arrangement for the drive of each of the wheels.