Riveted Sheet-Metal Control Arm Without Welding Corrosion
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Solution Overview
Problem
Current suspension control arms face challenges in achieving high stiffness and strength while maintaining low mass, with existing manufacturing methods being costly and prone to welding-related issues such as corrosion, misalignment, and reduced fatigue performance.
Innovation Solution
A suspension control arm constructed from pre-coated, lightweight sheet metal components formed through press-forming, joined without welding using rivets, which simplifies the manufacturing process, reduces material costs, and enhances structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to join control arm components, then structural strength is improved, but corrosion resistance deteriorates and manufacturing complexity increases
Solution Approach 1:
The patent removes the welding process entirely from the control arm manufacturing. Instead of welding sheet metal components together, the invention uses mechanical fastening systems (bolts, rivets, or press-fit mechanisms) to join pre-formed control arm sections, thereby extracting the harmful welding operation while maintaining structural integrity through alternative joining methods
Solution Approach 2:
The patent introduces intermediate fastening elements (such as bolts, rivets, or press-fit connectors) as mediators between control arm components. These intermediaries replace the direct metallurgical bond of welding with a mechanical connection that preserves the corrosion-resistant properties of the base materials while achieving the necessary structural strength
2Strength
If complex manufacturing processes like casting or forging are used, then strength and stiffness are improved, but manufacturing cost increases
Solution Approach 1:
The patent divides the control arm into multiple separable sheet metal components that can be manufactured using simple, low-cost press-forming processes. Instead of creating one complex cast or forged piece, the invention segments the control arm into sections that are easier and cheaper to manufacture individually, then joins them through mechanical fastening
Solution Approach 2:
The patent employs inexpensive sheet metal stampings instead of expensive cast or forged components. The sheet metal material and forming processes are significantly cheaper than traditional manufacturing methods, and while the individual components may require replacement sooner than cast parts, the overall system cost is reduced through lower material and manufacturing expenses
3Strength
If material is concentrated around edges to maximize second moment of area, then in-plane stiffness is improved, but weight increases
Solution Approach 1:
The patent applies local quality by concentrating material only where structurally necessary within the control arm components. The sheet metal sections are formed with varying thicknesses and geometries that place material strategically at critical locations (such as near mounting points and load-bearing areas) while leaving other areas thinner or open, achieving the required second moment of area and stiffness without unnecessary weight
Solution Approach 2:
The patent creates a composite structure by assembling multiple sheet metal components with different geometries and material distributions. Each component is optimized locally for its specific function, and the combination of these components achieves the overall structural performance needed, effectively creating a composite system that balances stiffness and weight through the integration of multiple optimized parts
Data Source
AI summary
A vehicular suspension control arm comprises a first arm component and a second arm component formed from sheet metal, each arm component comprising an outer wall and two side walls, bushing connecting means adjacent a first end, at least one bracket receiving rivet aperture adjacent a second end, at least one component connecting rivet aperture located between the first end and the second end, a ride bushing and a handling bushing, a ball joint bracket comprising bracket rivet apertures corresponding to the at least one bracket receiving rivet aperture adjacent the second end of each of the first and second arm components and a plurality of rivets. When constructed, the ball joint bracket is riveted to both the first and second arm components adjacent the second end thereof via the at least one bracket receiving rivet aperture and the corresponding at least one bracket rivet aperture, the first arm component is riveted to the second arm component at the at least one component connecting rivet aperture, the ride bushing is connected at the first end of the first arm component and the handling bushing is connected at the first end of the second arm component.