Shell-Type Wishbone With Channel Profiles For Weight Reduction
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Solution Overview
Problem
Conventional wishbones with welded shell parts have sharp edges and weld seams at the outer edges, which require additional space for tire clearance and are subjected to high stresses, leading to increased weight due to thicker weld seams and sheet metal thickness.
Innovation Solution
A shell-type wishbone composed of at least three channel-shaped profile shells with weld seams relocated to less stressed areas, such as the top and bottom, and integrated bearing components, allowing for reduced material and weld seam thickness while maintaining strength and rigidity, and incorporating different sheet metal thicknesses and materials for optimized stress distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If weld seams are located at the outer edges of the wishbone, then the structural integrity is maintained, but the weight increases due to thicker weld seams and sheet metal required to withstand high stresses
Solution Approach 1:
The weld seams are relocated from the outer edge region (lateral dimension) to the inner region (central dimension) of the wishbone. This dimensional relocation moves the weld seams from high-stress areas to low-stress areas, allowing for thinner weld seams and reduced sheet metal thickness while maintaining structural integrity, thus reducing overall weight
2Ease of manufacture
If the wishbone has conventional single-shell or two-shell construction with edge welding, then manufacturing is simplified, but sharp edges are created requiring additional tire clearance space
Solution Approach 1:
The wishbone is divided into three separate shell parts instead of one or two conventional shells. This segmentation allows each shell to be formed without sharp outer edges, as the channel-shaped profiles have rounded contours. The multiple shells are then joined to form the complete wishbone structure, eliminating the need for additional tire clearance space while maintaining ease of manufacture through standardized profile components
Solution Approach 2:
The three shell parts are designed as channel-shaped profile shells with curved, rounded outer surfaces instead of sharp edges. This curvature eliminates the need for additional tire clearance space that would be required for sharp edges, while the channel-shaped cross-section maintains structural strength and rigidity
3Strength
If thicker sheet metal and weld seams are used to withstand high stresses at outer edges, then the strength and rigidity are ensured, but the component weight increases
Solution Approach 1:
Different regions of the wishbone are assigned different shell thicknesses based on their stress requirements. The inner region where weld seams are located uses thinner material since it experiences lower stresses, while the outer regions maintain sufficient thickness for strength. This localized quality optimization reduces overall material usage and weight while ensuring adequate strength and rigidity where needed
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 solution reduces the weight of the wishbone by minimizing material and weld seam thickness while maintaining strength and rigidity, and improves space utilization at the wheel-side connection by eliminating sharp edges and reducing stress on weld seams.
Implementation Method 1
at least three shell parts that are welded together to form a hollow body
Data Source
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AI summary
The invention relates to a shell-type control arm (1) for a wheel suspension of a motor vehicle, comprising at least three shell sections welded together to form a hollow body (5) which has at least three bearing connection areas (6, 7, 8). To create a control arm of this type that allows for improved use of installation space at the wheel-side connection in the tire area and still offers the required strength and stiffness at a low component weight, the invention proposes that the shell sections be designed as channel-shaped profile shells (2, 3, 4), each of which defines an outer, U-shaped cross-sectional edge section (2.1, 3.1, 4.1) of the hollow body (5), and each pair of the channel-shaped profile shells (2, 3, 4) forming one of the at least three bearing connection areas (6, 7, 8).