Subframe Assembly with Modular Blocks for Suspension Configurations
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Solution Overview
Problem
Current suspension modules for heavy vehicles lack a standardized and cost-effective design for constructing different configurations, particularly in supporting steering and non-steering subsystems, which complicates manufacturing and increases tooling costs.
Innovation Solution
A suspension module with a subframe assembly that includes a lower subframe with a skid plate, subframe blocks, and upper control arm mounting plates, allowing for pivotally supported control arms and standardized subframe block configurations to facilitate various suspension module constructions, reducing tooling and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a standardized subframe block configuration is used, then manufacturing cost is reduced and device complexity is simplified, but adaptability to different suspension configurations is limited
Solution Approach 1:
The subframe blocks are designed with universal mounting capabilities that allow them to support multiple suspension configurations. The blocks include standardized mounting locations for control arms, dampers, and steering components, enabling the same basic block structure to serve different functional requirements through selective component attachment rather than requiring different block designs for each configuration.
Solution Approach 2:
The subframe is divided into modular blocks that can be selectively assembled and configured. Each block is a discrete, standardized unit that can be independently manufactured and then combined in different arrangements to create various suspension configurations, including steering and non-steering applications.
2Adaptability or versatility
If multiple specialized subframe designs are created for different configurations, then adaptability to various suspension types is improved, but device complexity and tooling costs increase
Solution Approach 1:
Instead of creating specialized subframe designs for different suspension types, the invention uses a universal subframe block design that can accommodate multiple configurations. The same basic block structure supports various control arm arrangements, steering mechanisms, and damper configurations through standardized mounting interfaces and selective component placement.
Solution Approach 2:
The subframe design allows for dynamic reconfiguration through the selective assembly and arrangement of standardized blocks and components. The system can be adapted to different suspension configurations by changing the arrangement and attachment of components to the standardized blocks rather than requiring fundamentally different subframe structures.
3Adaptability or versatility
If multiple specialized subframe designs are created for different configurations, then adaptability to various suspension types is improved, but manufacturing cost and productivity are reduced
Solution Approach 1:
The standardized subframe blocks serve multiple suspension configurations, allowing a single tooling setup to produce blocks that can be used in various applications. This eliminates the need for separate tooling for each configuration type, thereby maintaining high manufacturing efficiency while providing configuration versatility.
Solution Approach 2:
By segmenting the subframe into standardized, modular blocks, the invention enables efficient production through repeated manufacturing of identical or similar components. This modular approach allows for streamlined production processes, inventory management, and assembly operations while still accommodating different suspension configurations through selective component combination.
Data Source
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AI summary
A suspension module having a subframe assembly. The subframe assembly includes a lower subframe that pivotally supports at least one lower control arm. An upper control arm mounting plate is mounted to the lower subframe. The upper control arm mounting plate pivotally supports an upper control arm.