Variable Thickness Suspension Arm for Impact Deformation
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Solution Overview
Problem
Motor vehicle suspension arms deform undetectably during low-speed impacts, risking further damage and breakage, and existing reinforcement methods add weight and cost without ensuring deformation is visible to the user.
Innovation Solution
A suspension arm with a base structure formed from a metal plate of varying thickness, where the portion connected to the wheel has a greater thickness than the portion connected to the chassis, creating a privileged deformation zone that is noticeable without adding reinforcement parts, thus protecting the wheel and chassis connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcement pieces are attached to the sheet metal plate, then the resistance of the suspension arm is improved, but the weight and material cost increase
Solution Approach 1:
The suspension arm employs variable thickness of the sheet metal plate along its length, with the thickest section located at the central region and progressively thinner sections toward the ends. This local quality variation provides enhanced strength and resistance where impacts are most likely to occur, while maintaining lower weight in less critical areas, eliminating the need for additional reinforcement pieces
Solution Approach 2:
The invention changes the geometric parameter of the sheet metal plate by varying its thickness throughout the structure. This parameter change creates an optimized strength-to-weight ratio, providing sufficient resistance against impacts without the need for additional reinforcement components that would increase weight and material cost
2Reliability
If the suspension arm is made stronger to prevent deformation, then the reliability is improved, but the cost of material increases
Solution Approach 1:
The variable thickness design provides localized strengthening at the central region of the suspension arm where structural integrity is most critical, while using less material in the end sections. This approach ensures adequate protection against deformation and breakage without requiring excessive material throughout the entire structure, thereby controlling material costs
Solution Approach 2:
By changing the thickness parameter of the sheet metal plate along its length, the invention achieves optimal structural reliability where needed most while minimizing overall material consumption, thus preventing deformation without incurring excessive material costs
3Ease of manufacture
If the suspension arm uses uniform thickness, then the manufacturing is simplified, but the deformation is not detectable and may lead to breakage
Solution Approach 1:
The variable thickness design creates a specific geometric configuration where the transition from thicker to thinner sections produces visible changes in the suspension arm's orientation and position after deformation. This local quality variation enables deformation detection while maintaining manufacturing simplicity through a single-piece stamped construction without complex assemblies
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 allows for visible deformation detection without immediate breakage, maintaining structural integrity and preventing unnecessary weight and material costs, ensuring the user is aware of the deformation without compromising the vehicle's stability.
Implementation Method 1
a privileged place of deformation is created between the first portion and the second portion. In the event of an impact, this is where the suspension arm will deform
Data Source
Figure 1~2
AI summary
The invention relates to a suspension arm (1) of a vehicle, comprising a base structure (10) formed form a metal plate and comprising: a first portion (11) to be attached to a wheel of a vehicle; and a second portion (12) to be attached to the chassis of the vehicle, characterised in that the metal plate is thicker in the first portion than in the second portion.