Modular Corner Suspension Layout for Low-Floor Vehicle Bodies
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Solution Overview
Problem
Existing vehicle suspension systems with integral axle suspension and air springs do not effectively improve ride comfort and handling characteristics, and the upright shock absorbers in corner modules reduce internal vehicle space.
Innovation Solution
A vehicle body structure configured for modular assembly, featuring a chassis frame with corner modules that include a knuckle, upper arm, elastic member, and shock absorber, which are designed to minimize space usage and enhance torsional strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If upright shock absorbers are used in corner modules, then suspension performance is improved, but internal vehicle space is reduced
Solution Approach 1:
The shock absorber is reoriented from a vertical arrangement to a diagonal arrangement, changing its spatial orientation from the vertical dimension to a diagonal dimension. This dimensional change allows the shock absorber to maintain its suspension function while occupying different spatial volume, thereby preserving more internal vehicle space below the floor.
2Ease of operation
If integral axle suspension with air springs is used, then ride comfort should be improved, but handling characteristics and torsional strength are insufficient
Solution Approach 1:
The suspension system is segmented into independent corner modules, each with its own shock absorber and elastic member. This segmentation allows each corner to be optimized independently, combining the ride comfort benefits of air springs with the torsional strength of rigid shock absorbers in a modular configuration.
Solution Approach 2:
The system combines air springs (flexible, comfort-oriented) with rigid shock absorbers and elastic members (strength-oriented) in a composite suspension system. This composite approach integrates the advantages of both flexible and rigid components to achieve both ride comfort and torsional strength.
3Ease of manufacture
If corner modules are designed with traditional structures, then assembly is simplified, but fabrication processes become complex and space is reduced
Solution Approach 1:
The vehicle body is divided into modular corner modules that can be assembled independently. Each module contains integrated components (knuckle, shock absorber, elastic member, brake assembly) that are pre-configured as complete functional units, simplifying the overall assembly process while managing fabrication complexity at the module level.
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
The modular vehicle body structure minimizes fabrication processes, maintains internal vehicle space, and provides improved torsional strength and ride comfort by utilizing a low-floor design and advanced materials like CFRP for the elastic member.
Implementation Method 1
an elastic member mounted between the module bracket and a bottom end portion of the knuckle
Implementation Method 2
a shock absorber including a first end portion coupled to the upper arm and a second end portion fastened to an elastic bracket located on the elastic member
Data Source
AI summary
A vehicle body structure capable of modular assembly includes a chassis frame extending from a body frame forming a vehicle body. A corner module is fastened to a side portion of the chassis frame. The corner module includes a knuckle fastened to a wheel, an upper arm positioned between a top end portion of the knuckle and a module bracket mounted on the chassis frame, and an elastic member mounted between the module bracket and a bottom end portion of the knuckle.