Integrated Suspension Carrier Structure for Lower Unsprung Mass
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Solution Overview
Problem
Eco-friendly vehicles, such as hybrid and electric vehicles, face increased unsprung mass due to the weight of batteries, leading to decreased ride comfort and the need for technologies that reduce unsprung mass while maintaining suspension rigidity.
Innovation Solution
A suspension apparatus with a body connector and carrier design that integrates a main body connector, carrier, and link connectors, utilizing different materials and coupling reinforcement portions to enhance coupling strength and reduce unsprung mass, achieved through a manufacturing method involving casting and integration of components without additional coupling members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional suspension components are used with multiple coupling members, then connection strength is maintained, but unsprung mass increases
Solution Approach 1:
The patent integrates the body connector and carrier into a single unified component structure. The body connector includes integrated features such as the body connection hole, carrier connection portion, and link connection portions that are formed as one piece, eliminating the need for separate coupling members and reducing unsprung mass while maintaining connection strength
Solution Approach 2:
The suspension apparatus utilizes composite material construction where the body connector and carrier are formed from materials optimized for both strength and weight reduction. The integration of these components allows for material selection and structural design that achieves high strength-to-weight ratio, reducing unsprung mass without compromising connection strength
2Manufacturing precision
If multiple separate components are used for suspension assembly, then manufacturing flexibility is maintained, but tolerance accumulation increases
Solution Approach 1:
By merging the body connector and carrier into an integrated structure with unified manufacturing, the patent eliminates tolerance accumulation that would occur through assembly of multiple separate components. The single integrated structure ensures consistent dimensional relationships without the need for precise tolerance control across multiple mating surfaces and fasteners
3Ease of manufacture
If additional coupling members are used to connect components, then connection reliability is improved, but manufacturing cost increases
Solution Approach 1:
The integration of body connector and carrier into a single component eliminates the need for separate coupling members such as bolts, nuts, or welds, thereby reducing manufacturing steps, material costs, and assembly operations while maintaining connection reliability through the unified structural design
Solution Approach 2:
The patent extracts and eliminates the separate coupling members from the suspension assembly, retaining only the essential functional components. This removal of unnecessary intermediate elements reduces manufacturing complexity and cost while the integrated design ensures reliable connections through optimized structural features
Data Source
AI summary
A suspension apparatus and a method therefor are provided. The suspension apparatus includes a body connector including a main body connector provided with a body connection hole, and a carrier including a carrier hole which extends from the body connector and into which a wheel bearing is inserted, a caliper connector connected to a caliper, and a link connector connected to a link and configured to rotate with respect to the body connection hole.