Vehicle Suspension Bracket Design for Stress Distribution
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Solution Overview
Problem
Existing fastening means for vehicle suspension frames concentrate stress at narrow zones, leading to increased weight and risk of breakage, as they are not effectively distributing the tension acting on the frame.
Innovation Solution
A fastening assembly with brackets that are folded twice to enclose longitudinal and supporting frames, distributing forces over a wide contact surface and reducing localized stress concentrations, thereby reducing the weight of the assembly and the vehicle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If U-shaped brackets and supports are directly welded to the frame sections, then the suspension can be fixed to the frame, but the stress concentrates at narrow zones, increasing the weight of the frame sections
Solution Approach 1:
The bracket connecting portion is folded twice to create a three-dimensional structure that wraps around the longitudinal member, transforming a simple planar connection into a volumetric enclosure. This dimensional change allows the bracket to distribute forces across multiple contact surfaces (inner face, outer face, and end surfaces) rather than concentrating stress at a single narrow zone, thereby reducing the required frame section weight while maintaining fastening reliability
Solution Approach 2:
The bracket connecting portion is designed to enclose the longitudinal member in a nested configuration, with the bracket walls surrounding and partially enclosing the frame member. This nesting arrangement creates multiple contact interfaces between the bracket and longitudinal member, distributing the mechanical loads across a wider area and reducing stress concentrations that would otherwise require heavier frame sections
2Strength
If the frame sections are made with large size to oppose stresses, then the stress concentration risk is reduced, but the vehicle weight increases considerably
Solution Approach 1:
By folding the bracket connecting portion twice to create a three-dimensional enclosing structure, the invention distributes stresses across multiple spatial dimensions and contact surfaces. This allows the use of lighter frame sections while maintaining adequate strength, as the bracket's volumetric configuration provides superior stress distribution compared to conventional planar weldments
Solution Approach 2:
The folded bracket connecting portion serves multiple functions simultaneously: it provides structural support, distributes mechanical loads across the longitudinal member, and creates multiple contact surfaces for stress distribution. This multi-functionality allows a single component to replace what would otherwise require heavier frame sections designed solely for strength
3Weight of moving object
If the fastening means weight is reduced, then the vehicle weight decreases, but the risk of breakage at stressed zones increases
Solution Approach 1:
The twice-folded bracket creates a three-dimensional structure that encloses the longitudinal member, distributing forces across multiple contact surfaces including inner faces, outer faces, and end surfaces. This volumetric stress distribution maintains fastening reliability even with reduced fastening means weight, as the multi-contact configuration prevents stress concentration at any single point
4Ease of manufacture
If U-shaped brackets are used to fasten suspension, then the suspension can be anchored to the frame, but localized tension increases at narrow zones
Solution Approach 1:
The bracket connecting portion is folded twice to create a three-dimensional enclosing structure that contacts the longitudinal member at multiple locations (inner face, outer face, and end surfaces). This volumetric configuration distributes localized tension across the entire enclosed area rather than concentrating it at narrow zones, while the bracket's simple folded geometry maintains ease of manufacture
Data Source
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AI summary
A fastening assembly (1) for anchoring a suspension (S) to a vehicle frame (T). The frame (T) comprises an upper portion (U) with at least one pair of longitudinal members (L) and a lower portion with at least one front mounting rack (A) and a rear mounting rack (P) with respective support frames (Ca, Cp) for axles (F) of wheels (R). Each suspension (S) comprises at least one shock absorbing member (D) and at least one wishbone (B) with an inner end hinged to the frame (T) and an outer end fixed to a wheel pin (F). The assembly comprises at least one upper bracket (2) anchorable to a longitudinal member (L) of the frame for fastening the head of a shock absorbing member (D), at least one lower bracket anchorable (3) to a respective supporting frame (Ca Cp) of each mounting rack (A, P) in a substantially centered position with respect to the upper bracket (2) for hinging the inner ends of the wishbone (B). Each of the brackets (2, 3) has a connecting portion (4, 5) to the frame (T) suitably shaped for at least partially enclosing a respective longitudinal member (L) and a respective frame (Ca, Cp), in a manner so as to distribute the forces acting on the wishbone and on the shock absorbing member over a relatively wide contact surface and avoid localized stress concentrations.