Description:A SUSPENSION ARM ASSEMBLY FOR MOUNTING ON A VEHICLE
TECHNICAL FIELD
[0001] The present disclosure, in general, relates to a suspension arm assembly, and more particularly to a rod end mounting point for 3-Point suspension arm.
BACKGROUND

[0002] In existing designs, arms are not mounted on a vehicle body directly, rather the arm is mounted on frame via a suspension bushing, which in-turn is mounted on the body. In some designs, bolted joints are used that may cause looseness and joint failure issues.
[0003] Fig. 1a and 1b illustrate images 100a and 100b depicting a conventional 3-point A-Arm design with an arm mounted on frame via a suspension bushing, in accordance with an existing prior art. The above-mentioned design may not allow for arms to be directly mounted on the body.
[0004] Fig. 2a and 2b illustrate images 200a and 200b depicting a combination of rod and a 2-point suspension arm connected via bolted joint, in accordance with an existing prior art. The above-mentioned combination provides the benefit of mounting rod directly to the body with axially mounted bushings, which helps in transferring load directly on body and stiffness can be tuned accurately via bushings. This combination, however, may include a number of drawbacks as mentioned below
[0005] a) Rod and arm are joined via bolted joint which is susceptible to bolt looseness and failure issues in fatigue conditions.
[0006] b) Rod design must be with minimum bends else strength decreases drastically in longitudinal loading conditions.
[0007] c) As rod cannot be curved/bent packaging of callipers and tires are a big challenge.
[0008] One of the conventional solutions discloses a suspension arm where the size of the straight rod is increased. However, where the size of the straight rod is increased, size of the base sheet metal arm also increases, leading to additional weight.
[0009] Thus, there is a need for a solution to overcome above mentioned drawbacks.
OBJECTS OF THE DISCLOSURE
[0010] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed herein below.
[0011] It is a general or primary object of the present subject matter to provide a suspension arm assembly for mounting on a vehicle, having a reinforcement structure attached to a sheet metal. The reinforcement structure receives a straight rod to enable an axial mounting of bushings directly onto the body member to provide better tunability of a load transfer and system stiffness.
[0012] It is another object of the present subject matter to provide a suspension arm assembly with increased rigidity.
[0013] It is another object of the present subject matter to optimally transfer a load from a suspension arm to a vehicle body via a mounting rod.
[0014] These and other objects and advantages will become more apparent when reference is made to the following description and accompanying drawings.

SUMMARY
[0015] This summary is provided to introduce concepts related to a suspension arm assembly. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
[0016] The present disclosure provides a suspension arm assembly for mounting on a vehicle. The suspension arm assembly comprises a sheet metal part, a reinforcement bracket structure received in the sheet metal part, and a straight rod received in the reinforcement bracket structure, to be attached to the vehicle. The straight rod is permanently attached to the reinforcement bracket structure.
[0017] In an aspect of the present subject matter, the reinforcement bracket structure comprises a first portion having a base surface with a first end and a second end, having a pocket extending between the first end and the second end to receive the straight rod, an emboss structure located at the second end, to provide strength and rigidity to the reinforcement bracket structure, and a tapered surface, extending downward in a slanting orientation from the second end, configured to provide an optimal load transfer from the first portion. The reinforcement bracket structure further includes a step portion with a front end and a rear end, having one or more intermediate weld spots, attached to the first portion via the front end. The reinforcement bracket structure also includes a second portion with a front portion, a rear portion, a first side, a second side opposite to the first side, attached to the second end of the step portion from the front portion, having a contoured profile on the rear portion. The rear portion and the second side are welded to the sheet metal part.
[0018] In an aspect of the present subject matter, the base surface comprises a first edge and a second edge on each side. The first edge and the second edge is welded with the sheet metal part for a permanent attachment with the sheet metal part.
[0019] In an aspect of the present subject matter, the pocket comprises a first pocket blend and a second pocket blend on each side to be welded with the straight rod for permanently attaching the straight rod to the reinforcement bracket structure.
[0020] In an aspect of the present subject matter, the tapered surface comprises a first inclined edge and a second inclined edge on each side. The first inclined edge and the second inclined edge are permanently attached to the sheet metal part by welding.
[0021] In an aspect of the present subject matter, the second portion comprises a side flange extending from the second portion and terminating at the rear end of the second portion to be welded with the sheet metal part to permanently attach the reinforcement bracket structure to the sheet metal part.
[0022] In an aspect of the present subject matter, the side flange of second portion is welded to the sheet metal part from a portion of the side flange attached to the second side and the rear end.
[0023] In an aspect of the present subject matter, the contoured profile of the first side of the second portion provides an optimal stress distribution across the reinforcement bracket structure.
[0024] In an aspect of the present subject matter, the step portion is welded to the sheet metal part via the one or more intermediate weld spots.
[0025] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The illustrated embodiments of the subject matter will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:
[0027] Fig. 1a and 1b illustrate images and depicting a conventional 3-point A-Arm design with an arm mounted on frame via a rear suspension bushing, in accordance with an existing prior art; and
[0028] Fig. 2a and 2b illustrate images and depicting a combination of rod and a 2-Point suspension arm connected via bolted joint, in accordance with an existing prior art;
[0029] Fig. 3 illustrates a diagram depicting a suspension arm assembly, in accordance with an embodiment of the present subject matter;
[0030] Fig. 4 illustrates the reinforcement bracket structure of the suspension arm assembly, in accordance with an embodiment of the present subject matter;
[0031] Fig. 5 illustrates an image depicting the first portion of the reinforcement bracket structure, in accordance with an embodiment of the present subject matter;
[0032] Fig. 6 illustrates an image depicting a number of welding zones on the reinforcement bracket structure, in accordance with an embodiment of the present subject matter; and
[0033] Fig. 7 illustrates an image depicting load transfer path along with high stress concentration areas in the suspension arm assembly, in accordance with an embodiment of the present subject matter.
DETAILED DESCRIPTION
[0034] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
[0035] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0036] Fig. 3 illustrates a diagram 300 depicting a suspension arm assembly 302, in accordance with an embodiment of the present subject matter. The suspension arm assembly 302 may be a 3-Point suspension arm for mounting on a vehicle body suitable for light commercial vehicles that require a high loading capacity and stiffness. The suspension arm assembly 302 as disclosed in the present subject matter may offer a high rigidity and an optimal load transfer directly to the vehicle body. The suspension arm assembly 302 may offer a number of advantages. The number of advantages may include:
a. A better design with more packaging space for tires and callipers.
b. Better stiffness while eliminating a requirement of forging parts.
c. Elimination of bolted joint related failure modes.

[0037] Continuing with the above embodiment, the suspension arm assembly 302 may include a sheet metal part 304, a reinforcement bracket structure 306, and a straight rod 308. The sheet metal part 304 may serve as a housing for the straight rod 308, and the reinforcement bracket structure 306. The sheet metal part 304 may be housing the reinforcement bracket structure 306 and the reinforcement bracket structure 306 may be receiving the straight rod 308 from one end of the straight rod 308. The reinforcement bracket structure 306 may be permanently attached to the sheet metal part 304. In a preferred embodiment, the reinforcement bracket structure 306 may be welded from a number of points to the sheet metal part 304. Moving forward, the straight rod 308 upon being received by the reinforcement bracket structure 306, may be permanently attached to the reinforcement bracket structure 306 by welding.
[0038] Fig. 4 illustrates the reinforcement bracket structure 306 of a suspension arm assembly, in accordance with an embodiment of the present subject matter. The reinforcement bracket structure 306 may be a single piece equipment housed within a sheet metal part as referred in fig. 3. The reinforcement bracket structure 306 may be designed based on a topology analysis of the suspension arm assembly catering to a load path optimization. The reinforcement bracket structure 306 may be permanently attached to an inside of the sheet metal part. In a preferred embodiment, the reinforcement bracket structure 306 may be welded to the sheet metal part. Furthermore, the reinforcement bracket structure 306 may be configured to receive the straight rod 308 as discussed in the fig. 3. To this understanding, the reinforcement bracket structure 306 may be manufactured by stamping and machining process.
[0039] Subsequently, the reinforcement bracket structure 306 may be configured to provide an optimal stress distribution throughout the structure and may also provide a better load management. The reinforcement bracket structure 306 as disclosed in the present subject matter may be configured to keep a front mounting point on a body member itself to retain, leading to advantages in heavy leading application scenarios.
[0040] Continuing with the above embodiment, the reinforcement bracket structure 306 may have a first portion 402, a step portion 404, and a second portion 406. The step portion 404 may be attaching with the first portion 402 from one end and the second portion 406 from another end. Moving forward, the first portion 402 may have a base surface 408, an emboss structure 410, and a tapered surface 412. The base surface 408 may have a first end 402a and a second end 402b. The base surface 408 may be permanently attached to the sheet metal part by welding such that the reinforcement bracket structure 306 is permanently attached to the sheet metal part through the first portion 402. Further, the base surface 408 may include a pocket 408a extending between the first end 402a and the second end 402b configured to receive the straight rod 308 as referred in fig. 3. The pocket 408a may initiate from the first end 402a and terminate at a point close to the second end 402b. The pocket 408a may be configured to facilitate a connection between the first portion 402 of the reinforcement bracket structure 306 and the straight rod 308. In an embodiment, the first portion 402 may be designed in a way such that a first edge and a second edge of the first portion 402 may facilitate a welding connection with the sheet metal part 304.
[0041] Furthermore, the emboss structure 410 may be provided at the second end 402b. The emboss structure 410 may be configured to provide a strength and a rigidity to the reinforcement bracket structure 306. Moving forward, the tapered surface 412 may be extending downward in a slanting orientation from the second end 402b of the base surface 408. The tapered surface 412 may be configured to provide a structural strength and an optimal load transfer from the first portion 402 and reduce high stress spots in the suspension arm assembly.
[0042] To that understanding, the step portion 404 of the reinforcement bracket structure 306 may have a front end 404a and a rear end 404b. The step portion 404 may further include one or more intermediate weld spots 404c. In a preferred embodiment, the step portion 404 may be welded to the sheet metal part via the one or more intermediate weld spots 404c. Moving forward, the front end 404a may be permanently attached to the first portion 402 and the rear end 404b may be attached to the second portion 406 of the reinforcement bracket structure 306.
[0043] Subsequently, the second portion 406 of the reinforcement bracket structure 306 may include a front portion 414a and a rear portion 414b. The front portion 414a may be attached to the rear end 404b of the step portion 404. The second portion 406 may further include a first side 414c and a second side 414d. The first side 414c may have a contoured profile to provide an optimal stress distribution across the reinforcement bracket structure 306. To that understanding, the second side 414d of the second portion 406 may include a side flange 414e. The side flange 414e may extend from the second portion 406 and terminate at the rear portion 414b of the second portion 406. The side flange 414e may be configured to provide a mating area for a better distribution of load on the reinforcement bracket structure 306 and reduce stress on a weld joint with the sheet metal part. Further, the side flange 414e may be welded with the sheet metal part to permanently attach the reinforcement bracket structure 306 to the sheet metal part through the second portion 406. In a preferred embodiment, the side flange 414e may be welded to the sheet metal part from a portion of the side flange 414e attached to the second side 414d and the rear portion 414b.
[0044] Fig. 5 illustrates an image 500 depicting the first portion 402 of a reinforcement bracket structure, in accordance with an embodiment of the present subject matter. The first portion 402 may have the base surface 408 with the pocket 408a, the emboss structure 410, and the tapered surface 412 as referred in the fig. 2. The pocket 408a may be receiving a straight rod. The base surface 408 may also include a first edge 502a and a second edge 502b on each side of the base surface 408. The first edge 502a and the second edge 502b may be welded with a sheet metal part for permanently attaching the reinforcement bracket structure with the sheet metal part through the first portion 402. Further, the pocket 408a may be extending between the first end 402a and the second end 402b. The pocket 408a may initiate from the first end 402a and terminate at a point close to the second end 402b. The pocket 408a may include a first pocket blend 504a and a second pocket blend 504b on each side. The first pocket blend 504a and the second pocket blend 504b may be configured to be welded with the straight rod for permanently attaching the straight rod to the reinforcement bracket structure.
[0045] Furthermore, the emboss structure 410 may be located at the second end 402b. The emboss structure 410 may be configured to provide a strength and a rigidity to the reinforcement bracket structure. Moving forward, the tapered surface 412 may be extending downward in a slanting orientation from the second end 402b of the base surface 408. The tapered surface 412 may be configured to provide an optimal load transfer from the first structure. To that understanding, the tapered surface 412 may have a first inclined edge 506a and a second inclined edge 506b on each side. The first inclined edge 506a and the second inclined edge 506b may be welded to the sheet metal part to permanently attach the reinforcement bracket structure with the sheet metal part. The first edge 502a, the second edge 502b, the first inclined edge 506a and the second inclined edge 506b may increase a mating area between the reinforcement bracket structure and the sheet metal part. The increase in the mating area may reduce stress spots on the suspension arm assembly 302 at one or more bending prone regions, further improving a bending strength during heavy braking loads.
[0046] Fig. 6 illustrates an image 600 depicting a number of welding zones on the reinforcement bracket structure 306, in accordance with an embodiment of the present subject matter. The number of welding zones may include a number of points through which the straight rod 308 is permanently attached to the reinforcement bracket structure 306 and the reinforcement bracket structure 306 is permanently attached to the sheet metal part 304. The number of points may include points at which first edge 502a, the second edge 502b, the first inclined edge 506a, the second inclined edge 506b, and the side flange 414e are welded to the sheet metal part 304 and the points at which the first pocket blend 504a and the second blend 504b is welded to the straight rod 308.
[0047] Fig. 7 illustrates an image 700 depicting load transfer path along high stress concentration areas in the suspension arm assembly 302, in accordance with an embodiment of the present subject matter.
[0048] While the detailed description describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions, or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.
, Claims:We claim:
1. A suspension arm assembly (302) for mounting on a vehicle comprising:
a sheet metal part (304);
a reinforcement bracket structure (306) receiving in the sheet metal part (304); and
a straight rod (308) received in the reinforcement bracket structure (306), to be attached to the vehicle, wherein the straight rod (308) is permanently attached to the reinforcement bracket structure (306).
2. The suspension arm assembly (302) as claimed in claim 1, the reinforcement bracket structure (306) comprises:
a first portion (402) further having,
a base surface (408) with a first end (402a) and a second end (402b), having a pocket (408a) extending between the first end (402a) and the second end (402b) to receive the straight rod (308);
an emboss structure (410) located at the second end (402b), to provide strength and rigidity to the reinforcement bracket structure (306); and
a tapered surface (412), extending downward in a slanting orientation from the second end (402b), configured to provide an optimal load transfer from the first portion (402);

a step portion (404) with a front end (404a) and a rear end (404b), having one or more intermediate weld spots (404c), attached to the first portion (402) via the front end (404a); and

a second portion (406) with a front portion (414a), a rear portion (414b), a first side (414c), a second side (414d) opposite to the first side (414c), attached to the second end (402b) of the step portion (404) from the front portion (414a), having a contoured profile on the rear portion (414c), wherein the rear portion (414b) and the second side (414d) are welded to the sheet metal part (304).

3. The suspension arm assembly (302) as claimed in claim 2, wherein the base surface (408) comprises a first edge (502a) and a second edge (502b) on each side, further wherein the first edge (502a) and the second edge (502b) are welded with the sheet metal part (304) for a permanent attachment with the sheet metal part (304).
4. The suspension arm assembly (302) as claimed in claim 2, wherein the pocket (408a) comprises a first pocket blend (504a) and a second pocket blend (504b) on each side to be welded with the straight rod (308) for permanently attaching the straight rod (308) to the reinforcement bracket structure (306).
5. The suspension arm assembly (302) as claimed in claim 2, wherein the tapered surface (412) comprises a first inclined edge (506a) and a second inclined edge (506b) on each side, wherein the first inclined edge (506a) and the second inclined edge (506b) are permanently attached to the sheet metal part (304) by welding.
6. The suspension arm assembly (302) as claimed in claim 2, wherein the second portion (406) comprises a side flange (414e) extending from the second portion (406) and terminating at a rear end (404b) of the second portion (406) to be welded with the sheet metal part (304) to permanently attach the reinforcement bracket structure (306) to the sheet metal part (304).
7. The suspension arm assembly (302) as claimed in claim 2 or 6, wherein the side flange (414e) is welded to the sheet metal part (304) from a portion of the side flange (414e) attached to the second side (414d) and the rear end (404b).
8. The suspension arm assembly (302) as claimed in claim 2, wherein the contoured profile of the rear portion (414c) of the second portion (406) provides an optimal stress distribution across the reinforcement bracket structure (306).
9. The suspension arm assembly (302) as claimed in claim 2, wherein the step portion (404) is welded to the sheet metal part (304) via the one or more intermediate weld spots (404c).