Segmented Suspension Arm Link with Hemmed Flange Interconnection

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Solution Overview

Problem

Existing vehicle suspension members face challenges in achieving structural robustness, cost-effectiveness, and weight optimization due to complex manufacturing processes and interconnection methods that can lead to distortion and non-uniform thickness, which affect dimensional repeatability and stiffness.

Innovation Solution

A suspension member design utilizing two sheet metal components with hemmed flanges and mechanical interconnections, optionally with structural adhesive, to create a robust and lightweight assembly that optimizes geometry and interconnection methods for reduced material gauge and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding is used to interconnect stamped sheets, then structural strength is improved, but distortion due to heat input reduces dimensional repeatability

Engineering Contradiction:

Improvestructural strengthVSAvoiddimensional repeatability

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The suspension member is divided into multiple separate stamped sheet components that are interconnected through mechanical means (hemmed flanges, locking mechanisms) rather than welded as a single unit. This segmentation allows each component to be manufactured separately with consistent dimensions and then assembled without heat-induced distortion.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The welding process (thermal/mechanical system) is replaced with purely mechanical interconnection methods such as hemmed flanges and locking mechanisms. This substitution eliminates heat input and associated distortion while maintaining structural strength through mechanical engagement of the stamped components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If complex casting or forging processes are used, then structural robustness is improved, but manufacturing cost increases

Engineering Contradiction:

Improvestructural robustnessVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Instead of manufacturing a single complex casting or forging, the structure is segmented into multiple simpler stamped sheet components. These can be produced using high-volume, low-cost stamping processes and then assembled, significantly reducing manufacturing cost while maintaining structural robustness through the interconnected design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The suspension member uses a composite structure formed by interconnecting multiple stamped metal sheets. This composite approach achieves the structural robustness of a monolithic casting or forging while utilizing the cost advantages of stamping processes, creating a hybrid solution that combines benefits of different manufacturing methods.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If uniform sheet thickness is used, then manufacturing simplicity is improved, but weight optimization and stiffness are reduced

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidcomponent weight

Core Design Contradiction:

Ease of manufactureVSWeight of moving object

Solution Approach 1:

The sheet metal components feature variable thickness with local reinforcements (such as stiffening ribs, flanges, and locked portions) positioned strategically in areas requiring higher stiffness and strength. Other areas use thinner gauge material to reduce weight, optimizing the balance between manufacturing simplicity and performance requirements.

Inventive Principle:

Principle #3Local quality

4Strength

If thicker metal sheets are used, then structural strength is improved, but component weight and cost increase

Engineering Contradiction:

Improvestructural strengthVSAvoidcomponent weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The structural strength is achieved through the segmented, interconnected design of multiple stamped sheets with mechanical locking and hemmed flanges. This distributed structural approach allows the use of thinner individual sheet components while maintaining overall structural integrity, reducing weight compared to a single thick-sheet design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The multi-layer composite structure formed by interconnecting stamped sheets creates a lightweight yet strong assembly. The composite action of multiple thin sheets working together provides structural strength equivalent to or greater than a single thick sheet, while significantly reducing material weight and cost.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS8690176B2Suspension arm/link for motor vehicle and method for making same

Publication Date: 2014.04.08 MAGNA INTERNATIONAL INC

AI summary

A vehicle suspension component includes a first metal sheet having a center portion bounded by a first outer wall and a second outer wall. A second metal sheet includes a center portion in engagement with the center portion of the first sheet. The second sheet includes a first downturned wall engaging a surface of the first outer wall as well as a second downturned wall engaging a surface of the second outer wall. One of the first and second sheets includes a first hemmed flange portion wrapping around a first edge of the other of the first and second sheets and engaging another surface of the other first and second sheet. One of the first and second sheets includes a second hemmed flange portion wrapping around a second edge of the other of the first and second sheets and engaging another surface of the first and second sheets.