Modular Twist Beam Suspension with Material Segmentation
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Solution Overview
Problem
Existing twist beams for vehicle suspension lack an optimal strength-to-weight ratio and are not modular enough to accommodate different vehicle types and wheelbases effectively.
Innovation Solution
A twist beam design featuring separate inner and outer parts made of different materials, with adaptable bearing-receiving sections and modular connections, allowing for precise alignment and use on both sides of the vehicle, achieved through extruded profiles, sheet metal components, and various connection methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a twist beam is made from a single material to ensure uniform strength, then the strength is sufficient throughout, but the weight increases and manufacturing cost rises
Solution Approach 1:
The patent applies local quality by dividing the twist beam into two parts made of different materials: the inner part is made of a heavier, stronger material (such as steel) to handle high-stress regions near the bearing, while the outer part is made of a lighter material (such as aluminum alloy) for the less stressed sections. This ensures that each section has the appropriate material properties for its specific loading conditions, achieving sufficient overall strength while minimizing total weight.
2Strength
If a twist beam is designed as a single integrated component, then structural strength is maximized, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies segmentation by dividing the twist beam into two separate components (inner part and outer part) that are manufactured independently and then assembled together. This allows each part to be optimized for its specific manufacturing process and requirements, simplifying production while maintaining structural integrity through the controlled connection between parts.
3Strength
If a twist beam is designed with fixed geometry to ensure structural integrity, then strength is maintained, but adaptability to different vehicle types is reduced
Solution Approach 1:
The patent applies dynamics by making the twist beam modular and configurable. The inner and outer parts can be selectively assembled in different configurations, and the bearing-receiving sections can be oriented differently (e.g., aligned or offset) depending on the specific vehicle type and application requirements. This allows the same basic components to adapt to various wheelbases and vehicle geometries while maintaining structural integrity through proper connection design.
Data Source
AI summary
A twist beam for a suspension of a motor vehicle comprises a body-side inner part having a bearing-receiving section for receiving a body-side bearing, and a wheel carrier-side outer part having a bearing-receiving section for receiving a wheel carrier-side bearing, the outer part and the inner part being separate components which are made of different materials and are firmly connected to each other.