Vehicle Suspension Arm With Sheet Metal Body And Solid Head
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Solution Overview
Problem
Existing suspension devices for motor vehicle rear wheels face challenges in efficiently managing longitudinal shocks, as they require additional interface parts that increase manufacturing costs and are prone to faulty fixings, and traditional methods to directly mount the knuckle on the arm are either costly or weight-intensive.
Innovation Solution
A suspension device design where the arm body is formed by sheet metal, and a solid, forged or machined head is attached to the rear end, with reinforcement elements to absorb forces and a hydro-elastic joint for shock filtration, allowing the knuckle to pivot and return to a stable position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If an additional interface part is added between the arm and the knuckle carrier to enable direct mounting, then the manufacturing cost increases and the fixing reliability deteriorates, but the structural complexity is improved
Solution Approach 1:
The patent merges the interface part functions directly into the arm structure by integrating the knuckle carrier mounting features into the forged arm body. This eliminates the need for separate interface parts and reduces fixing points, thereby improving reliability while maintaining structural complexity.
Solution Approach 2:
The patent segments the arm into two distinct parts: a sheet metal body and a forged head. This segmentation allows each part to be optimized for its specific function - the sheet metal body for cost-effectiveness and lightness, and the forged head for structural integrity and direct knuckle mounting capability.
2Strength
If the knuckle is mounted directly on a solid arm produced by forging and machining or molding and machining, then the structural integrity is improved, but the weight and manufacturing cost increase
Solution Approach 1:
The patent applies local quality by using different manufacturing methods for different parts of the arm. The sheet metal body provides sufficient strength for the majority of the arm structure at low weight, while the forged head provides localized high strength and structural integrity where the knuckle mounting requires it.
Solution Approach 2:
The patent creates a composite structure combining sheet metal and forged metal components. This composite approach allows the arm to achieve overall structural integrity comparable to a fully forged arm while significantly reducing weight and manufacturing cost through the use of lighter sheet metal for the main body.
3Adaptability or versatility
If a solid head is attached to the sheet metal body of the arm, then the capability to directly receive the pivoting knuckle is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent merges the knuckle reception capability directly into the forged head component. The head is designed with integrated features including the knuckle mounting interface and the elastic return means housing, eliminating the need for separate interface parts and simplifying the overall manufacturing process.
Solution Approach 2:
The forged head acts as an intermediary component that bridges the sheet metal body and the knuckle. It provides the necessary structural interface for direct knuckle mounting while being attachable to the sheet metal body through standard welding or screwing processes, thus managing manufacturing complexity.
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
This design combines the cost-effectiveness and lightness of sheet metal-formed arms with a robust, solid head capable of receiving the knuckle, enhancing shock absorption and reducing stress concentrations, thereby improving the suspension's structural integrity and manufacturing efficiency.
Implementation Method 1
a stub axle which is capable of receiving a wheel rotating around a first transverse axis by means of a stub axle, the stub axle being pivotally mounted around a second transverse axis directly on the head of the arm with a determined deflection around a stable angular position towards which it is elastically returned
Implementation Method 2
an axle with an elastically torsionally flexible crosspiece which comprises at least one longitudinal arm
Implementation Method 3
the arm is equipped with reinforcement means which straddle an interface zone between the head and the body and which are intended to absorb part of the forces applied to the head in order to transmit them to the sheet metal body
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a suspension device (10) for at least one rear wheel (12) of a motor vehicle, which comprises: an axle (14) having a crossmember (18) that is resiliently flexible when twisted and comprises at least one longitudinal arm (16) having: a longitudinal body (20); and a head (24) forming a rear end section of the arm (16); a steering knuckle pin (26) which is mounted directly on the head (24) of the arm (16) so as to be pivotable about a second transverse axis (C) and so as to have a predetermined travel around a stable angular position to which it is resiliently returned; characterised in that the body (20) of the arm (16) is produced by forming a metal sheet, while the head (24) is formed by a solid element which is attached and secured to a free rear end (32) of the body (20).