Single-Shell Spring Control Arm U-Shaped Constriction Stiffness
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Solution Overview
Problem
Spring control arms for motor vehicles with electric drive experience component failure due to excessive axle load, primarily caused by deformation of side limbs, and existing solutions like increasing material thickness or adding reinforcing metal sheets result in increased weight and manufacturing costs.
Innovation Solution
A single-shell spring control arm with a U-shaped constriction between the spring support surface and the damper receiving section, which enhances stiffness without requiring thicker material or additional metal sheets, thereby maintaining low weight and favorable manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the material thickness of the sheet metal is increased to improve stiffness, then the bending stiffness of the spring control arm is improved, but the component weight and material costs increase considerably
Solution Approach 1:
The patent applies local quality by forming a U-shaped bead reinforcement specifically in the high-stress area between the spring support surface and the damper receiving section, rather than uniformly increasing the thickness of the entire component. This localized reinforcement provides the necessary bending stiffness where needed while keeping the overall component weight low.
Solution Approach 2:
The patent transitions from a two-dimensional thickness increase to a three-dimensional structural feature by forming a U-shaped bead that protrudes from the surface. This dimensional change creates additional structural support and moment of inertia in the critical area without requiring increased base material thickness.
2Strength
If additional reinforcing metal sheets or bridge plates are attached to the spring control arm, then the load capacity in the spring support area is improved, but the manufacturing complexity and costs increase
Solution Approach 1:
The patent merges the reinforcement feature directly into the spring control arm body by forming the U-shaped bead as an integrated part of the sheet metal component during the forming process. This eliminates the need for separate reinforcing sheets or bridge plates and their associated attachment operations, thereby reducing manufacturing complexity while maintaining load capacity.
3Strength
If additional reinforcing metal sheets are attached to the spring control arm, then the load capacity is improved, but the component weight increases
Solution Approach 1:
The U-shaped bead provides localized reinforcement exactly where the load capacity needs to be improved, between the spring support surface and the damper receiving section. This concentrated reinforcement in the critical area achieves the necessary strength without adding the weight of extensive additional metal sheets across the entire component.
Data Source
AI summary
The invention relates to a single-shell spring control arm formed of sheet metal for a wheel suspension of a motor vehicle, with upwardly directed side limbs connected to one another by a base, with a first end section for connection to a chassis girder, with a second end section for wheel-side connection, with a spring receiving section, which is located between the two end sections and has a spring support surface formed on the base, and with a damper receiving section formed between the spring receiving section and the second end section for connecting a shock absorber. In order to achieve at relatively low component weight and favorable manufacturing costs improved stiffness with respect to high axle loads, the invention provides that a U-shaped constriction is formed between the spring support surface and the damper receiving section, which constriction extends in the base and in the side limbs.