Universal Knuckle Design for Utility Vehicle Suspension
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Solution Overview
Problem
The existing suspension assembly for utility vehicles is complex and costly due to the knuckle's design, which requires separate manufacturing and inventory for right and left wheels, increasing production and inventory costs.
Innovation Solution
A simplified knuckle design with symmetrical first and second suspension arms and brake arms allows the knuckle to be switchably used for both right and left driving wheels by rotating it 180 degrees, reducing manufacturing and inventory costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate knuckles are manufactured for right and left wheels, then the structural integrity and functionality for each wheel is ensured, but the manufacturing cost and inventory control cost increase
Solution Approach 1:
The knuckle is designed with asymmetric features including a steering knuckle body with a first end and a second end, where the first suspension arm connects to the first end and the second suspension arm connects to the second end. The brake caliper mounting position is also asymmetrically arranged. This asymmetric design allows the knuckle to be manufactured as a single part that can be installed on either the right or left wheel by rotating it 180 degrees, thereby reducing manufacturing complexity and inventory costs while maintaining the required structural integrity and functionality for each wheel position
Solution Approach 2:
The knuckle is designed as a universal component that can serve both right and left wheel positions. The first suspension arm, second suspension arm, and brake caliper mounting structure are arranged to allow the same knuckle part to be rotated and installed on either side of the vehicle. This multi-functional design eliminates the need for separate right-specific and left-specific knuckles, reducing manufacturing variety and inventory requirements while ensuring proper structural performance at both wheel positions
2Reliability
If a complicated knuckle structure is used, then the suspension functionality is ensured, but the manufacturing cost increases
Solution Approach 1:
The knuckle is designed as an integrated single piece comprising the steering knuckle body, first suspension arm, second suspension arm, and brake caliper mounting structure. By segmenting the design into functional zones within a single monolithic structure, the patent eliminates the need for multiple separate parts and assembly operations, thereby reducing manufacturing complexity and cost while ensuring reliable suspension functionality through the unified structural design
Solution Approach 2:
The patent merges multiple functional elements (steering knuckle body, suspension arms, brake caliper mounting structure) into a single integrated knuckle component. This consolidation eliminates the need for separate manufacturing and assembly of individual parts, reducing manufacturing steps, labor costs, and quality control complexity while maintaining all necessary suspension and braking functionalities through the unified structure
Data Source
AI summary
A suspension assembly for a utility vehicle includes a knuckle having a boss, a first suspension arm extending radially outward from the boss, a second suspension arm extending radially outward from the boss in a direction opposite to the first suspension arm, a first brake arm extending radially outward from the boss near the first suspension arm, and a second brake arm extending radially outward from the boss near the second suspension arm. The knuckle can be switchably used for both of a right driving wheel and a left driving wheel. The suspension assembly further includes an upper arm connected to the first suspension arm, a lower arm connected to the second suspension arm, and a brake caliper connected to the first brake arm and the second brake arm.