Monocoque Suspension Support Structure for Dash Panel Rigidity
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Solution Overview
Problem
Existing suspension systems in monocoque vehicles face challenges in securely mounting an upper arm with sufficient rigidity at the front side of the dash panel, leading to potential deformation during frontal collisions, which compromises driver and passenger safety.
Innovation Solution
A suspension support structure that includes a shock absorber housing, mounting support members with closed cross-sections, and upper arm mounting brackets, which are aligned with dash cross members and a front side member to provide enhanced rigidity and minimize dash panel deformation during collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a multi-link type suspension is mounted with the upper arm disposed forward of the dash panel, then the occupancy space utilization is improved and costs are reduced, but the rigidity of the upper arm mounting is insufficient leading to dash panel deformation during frontal collisions
Solution Approach 1:
The mounting support member is divided into an inner member and an outer member that work together to provide enhanced mounting rigidity. The inner member is disposed inside the vehicle body with a closed cross-section, while the outer member is disposed outside, creating a segmented structure that distributes mounting loads and prevents dash panel deformation during collisions.
Solution Approach 2:
The mounting support member combines the inner member and outer member into a composite structure. The inner member provides structural support within the vehicle body cavity, while the outer member reinforces the mounting interface, creating a composite system that achieves sufficient rigidity for upper arm mounting while maintaining the forward disposition for space optimization.
2Device complexity
If the upper arm is mounted at the front side of the dash panel, then the vehicle structure is simplified and manufacturing costs are reduced, but the dash panel deforms during frontal collision accidents compromising safety
Solution Approach 1:
The mounting support member acts as an intermediary element between the upper arm and the dash panel. It provides a rigid mounting interface that isolates the dash panel from collision forces, allowing the upper arm to be mounted forward of the dash panel while preventing dash panel deformation that would compromise safety.
Solution Approach 2:
The mounting support member extends in the forward-rearward direction of the vehicle body, utilizing the dimensional space available. By positioning the inner member inside the vehicle body and the outer member outside, the structure leverages the third dimension to achieve rigidity without complicating the overall vehicle structure or increasing manufacturing complexity.
Data Source
AI summary
A shock absorber support structure for a monocoque vehicle includes a shock absorber housing disposed at an upper side of a front side member disposed at a front side of a dash panel, a mounting support member coupled to a lower side of a shock absorber mounting part of the shock absorber housing and coupled to face a plurality of dash cross members with the dash panel interposed therebetween, upper arm mounting brackets vertically connecting the mounting support member and the front side member and spaced apart from each other in a forward/rearward direction of a vehicle body, and an upper side member disposed at the upper side of the front side member and elongated in the forward/rearward direction of the vehicle body, the upper side member having a rear end coupled to a front side of the mounting support member.