Suspension Tower Rib Design for Rigidity
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Solution Overview
Problem
Existing suspension towers lack sufficient rigidity while trying to maintain low mass and dimensions, which affects their structural integrity and handling stability, especially under load conditions.
Innovation Solution
The suspension tower design incorporates a plate with a fixing portion and a gradually changing rib that extends from the axis towards the outer peripheral side, featuring a constant level portion and a gradually decreasing portion, where the boundary between these is positioned adjacent to the fixing portion, mitigating stress concentration and improving rigidity without increasing mass or dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the height or thickness of the rib is increased to improve rigidity, then the rigidity of the suspension tower improves, but the mass and dimensions of the suspension tower increase
Solution Approach 1:
The rib structure is changed from a conventional uniform design to a gradually changing design where the height decreases from the inner peripheral side toward the outer peripheral side. This parameter change allows the rib to provide sufficient rigidity near the fixing portion while reducing mass toward the outer edges, resolving the contradiction between rigidity and weight
Solution Approach 2:
The rib is designed with different heights at different locations: a constant level portion near the fixing portion for maximum rigidity, and a gradually decreasing portion toward the outer periphery for mass reduction. This local differentiation optimizes the balance between rigidity and weight
2Strength
If the height or thickness of the rib is increased to improve rigidity, then the rigidity of the suspension tower improves, but the dimensions of the suspension tower increase
Solution Approach 1:
The rib height parameter is varied continuously from the inner peripheral side to the outer peripheral side, creating a gradually changing structure that provides necessary rigidity near the fixing portion while minimizing overall dimensions, thus resolving the contradiction between rigidity and dimensions
Solution Approach 2:
Instead of increasing rib thickness (one-dimensional solution), the invention uses a three-dimensional gradually changing height profile that tapers toward the outer periphery, providing rigidity where needed while controlling overall dimensions
3Ease of manufacture
If a conventional uniform rib structure is used, then the manufacturing is simpler, but the stress concentration at the fixing portion cannot be effectively mitigated
Solution Approach 1:
The rib transitions from a uniform parameter design to a gradually changing parameter design, where the height varies continuously toward the outer periphery. This can be manufactured using progressive forming or additive manufacturing techniques, balancing manufacturing feasibility with stress concentration mitigation
Solution Approach 2:
The rib structure is differentiated into a constant level portion for structural support and a gradually decreasing portion for stress distribution, with the boundary positioned to optimize stress mitigation while remaining manufacturable
Data Source
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AI summary
A suspension tower (10) has: a top plate (14) at which an upper end side of a front suspension is fixed at a fixing portion that is disposed apart from a stroke axis (SA) of the suspension; and a gradually changing rib (20T) that is provided upright from the top plate (14) and extends from the stroke axis (SA) side toward an outer peripheral side at the top plate (14). The gradually changing rib (20T) has a constant level portion (20Ts) whose height from the fixing portion is constant, and a gradually changing portion (20Tc) whose height from the fixing portion is gradually decreased from the constant level portion (20Ts) toward the outer peripheral side. A boundary (20Tb) between the constant level portion (20Ts) and the gradually changing portion (20Tc) is disposed adjacent to the fixing portion.