Vehicle Suspension Tower Positioning via Adjustable Flanges

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Solution Overview

Problem

Existing vehicle body front structures require dedicated front side frames and suspension towers for each vehicle model due to fixed positional relationships, limiting the sharing of components across different vehicle models with varying suspension device mounting positions.

Innovation Solution

The vehicle body front structure incorporates inclined joint flanges in the front side frames and adjustable positioning flanges on the suspension towers, allowing the suspension towers to be fixed at multiple positions, enabling sharing across various vehicle models with different suspension device mounting configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If dedicated front side frames and suspension towers are used for each vehicle model, then structural integrity and precise positioning are ensured, but component sharing across different vehicle models is limited

Engineering Contradiction:

Improvestructural integrityVSAvoidcomponent sharing

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The suspension tower is designed with a movable positioning flange that can be adjusted to different fixation positions on the joint flange of the front side frame. This dynamic adjustment capability allows the same suspension tower to adapt to different vehicle models with varying suspension device mounting positions, enabling component sharing while maintaining proper structural positioning and integrity for each specific application.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The joint flange is designed with multiple fixation positions and the positioning flange can selectively engage with different positions, making the suspension tower universally applicable across multiple vehicle models. This multi-functionality allows a single suspension tower design to serve various mounting configurations, thereby enabling component sharing while ensuring each installation maintains the required structural integrity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple fixation positions are provided for suspension towers, then adaptability to different vehicle models is improved, but device complexity increases

Engineering Contradiction:

Improvemounting position flexibilityVSAvoidjoint structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The joint structure is segmented into distinct functional elements: the joint flange with multiple fixation positions and the positioning flange with selection capability. This segmentation allows the complexity to be distributed and managed through modular design, where each component has a specific function, making the overall system easier to manufacture and assemble despite the increased adaptability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The positioning flange is designed to be movable or adjustable, allowing it to be positioned at different fixation points on the joint flange. This dynamic element provides the necessary adaptability for different vehicle models without requiring multiple complete joint structures, thereby managing complexity while maintaining flexibility.

Inventive Principle:

Principle #15Dynamics

3Productivity

If component sharing is implemented across vehicle models, then manufacturing costs and weight are reduced, but positioning precision may be compromised

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidsuspension tower positioning

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The positioning flange is designed with the capability to be precisely positioned and fixed at specific fixation positions on the joint flange. This dynamic positioning ensures that even though the same component is used across different vehicle models, the suspension tower can be accurately positioned according to each vehicle model's specific requirements, maintaining manufacturing precision while enabling component sharing.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The design replaces the need for multiple dedicated mechanical structures with a single adjustable mechanical system. By using the movable positioning flange that can be fixed at different positions, the system achieves the same effect as multiple dedicated structures would provide, thereby reducing manufacturing complexity and cost while maintaining positioning precision through the fixed positions designed into the joint flange.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20240300586A1Vehicle body front structure

Publication Date: 2024.09.12 SUBARU CORP

AI summary

A vehicle-body front structure for a vehicle includes front side frames in a pair and suspension towers in a pair. The side frames are arranged in a vehicle width direction of the vehicle and extend in a vehicle body longitudinal direction of the vehicle. The suspension towers support upper portions of suspension devices and are disposed outside the front side frames in the vehicle width direction. Joint flanges are provided respectively in the front side frames and are inclined while extending to an upper outer side in the vehicle width direction respectively toward the suspension towers. Positioning flanges are provided in a lower end portion of the suspension towers respectively. Each of the positioning flanges is selectively fixed to a fixation position of two or more different fixation positions set in a corresponding one of the joint flanges.