[002] Various types of suspension systems for vehicles are known. One such
suspension system is double wishbone suspension system. As it will be appreciated by
those skilled in the art, the double wishbone suspension system is a type of road-to-vehicle
vibrations damping mechanism which allows each wheel of the vehicle to move vertically
without disturbing other wheels. For this reason, the double wishbone suspension system
is also known as an independent suspension system. This suspension system provides
freedom of controlling parameters responsible for governing the ride and handling
characteristics of the vehicle, such as camber, castor, scrub radius, toe, and position of the
roll center.
[003] The double wishbone type suspension system may include upper and lower
arms, knuckle, ball joints, connection mounts and some sort of damping mechanism. The
damping mechanism may include springs, dampers or a combination of both, depending
upon ride and handling requirements. The first ends of the upper and lower arms are
coupled to the chassis of the vehicle using mounting brackets, and run in transverse
direction with the damping mechanism. In other words, the upper and lower arms are
directly joined with the chassis of the vehicle using the mounting brackets. The second
ends of the upper and lower arms are joined with the knuckle using ball joints. The
knuckle also houses steering arm and wheel. Therefore, the complete load transfers
between chassis and road happens through three stages, as follows:
(road, tires, wheels) > (knuckle, upper and lower arms) > (chassis)
[004] However, in case of a failure of any component in such a suspension
system, the entire suspension system fails in performance. Further, repair and maintenance
of such a suspension system necessitates complete un-assembling of the suspension
3
system in order to perform the repair and maintenance operations. This proves timeconsuming, labor intensive, and costly.
[005] Some modular suspension frames are known which may couple with the
chassis of the vehicle. However, these modular suspension frames are welded to the
chassis, and are therefore permanently fixed to the chassis. Although, coupling the frame
using welding proves to be less time consuming, however, welding reduces the strength at
the joints and, therefore, makes the structure prone to failure. As the welded joints are
permanent joints, they have more complexities in process automation. Further, welded
joints hamper serviceability and maintenance of the suspension systems.
[006] Therefore, an improved suspension system which allows easy and quick
un-assembling and assembling, and which is capable of preventing failure through load
path optimization is desired.
SUMMARY
[007] In one embodiment, a modular suspension frame for coupling with a
chassis of a vehicle is disclosed. The modular suspension frame may include a base having
a left end and a right end. The modular suspension frame may further include a left-side
body positioned on the left end of the base. The left-side body may include a first left-side
member including a first left-side lower segment and a first left-side upper segment. The
first left-side lower segment may be inclined to the first left-side upper segment at a first
predefined angle. The modular suspension frame may further include a second left-side
member including a second left-side lower segment and a second left-side upper segment.
The second left-side lower segment may be inclined to the second left-side upper segment
at the first predefined angle. The modular suspension frame may further include a rightside body positioned on the right end of the base. The right-side body may include a first
right-side member including a first right-side lower segment and a first right-side upper
segment. The first right-side lower segment may be inclined to the first right-side upper
segment at a second predefined angle. The modular suspension frame may further include
a second right-side member including a second right-side lower segment and a second
right-side upper segment. The second right-side lower segment may be inclined to the
4
second right-side upper segment at the second predefined angle. The modular suspension
frame may further include a left mounting arm coupled to the left-side body, and a right
mounting arm coupled to the right-side body. The modular suspension frame may be
configured to be coupled with the chassis of the vehicle, via the left mounting arm and the
right mounting arm using a plurality of fasteners.
[008] In another embodiment, a vehicle is disclosed. The vehicle may include a
chassis and a modular suspension frame configured to be coupled with the chassis. The
modular suspension frame may include a base having a left end and a right end. The
modular suspension frame may further include a left-side body positioned on the left end
of the base. The left-side body may include a bend with a first predefined angle. The
modular suspension frame may further include a right-side body positioned on the right
end of the base. The right-side body may include a bend with the first predefined angle.
The modular suspension frame may further include a left mounting arm coupled to the
left-side body, and a right mounting arm coupled to the right-side body. The modular
suspension frame may be configured to be coupled with the chassis of the vehicle, via the
left mounting arm and the right mounting arm using a plurality of fasteners.
[009] It is to be understood that both the foregoing general description and the
following detailed description are exemplary and explanatory only and are not restrictive
of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[010] The accompanying drawings, which are incorporated in and constitute a
part of this disclosure, illustrate exemplary embodiments and, together with the
description, explain the disclosed principles.
[011] FIG. 1 illustrates a perspective view of a modular suspension frame, in
accordance with an embodiment of the present disclosure.
[012] FIG. 2A illustrates a perspective view of a modular suspension frame, in
accordance with another embodiment.
[013] FIG. 2B is a schematic diagram of front view of a modular suspension
frame, in accordance with another embodiment.
5
[014] FIG. 3A-3B illustrate a perspective view of a suspension system and a
magnified perspective view of the suspension system, respectively, of a vehicle, in
accordance with an embodiment.
[015] FIG. 4A-4C illustrate perspective views of a vehicle implementing a
modular suspension frame, in accordance with an embodiment.
[016] FIG. 5 is a flowchart of a method of assembling a suspension system of a
vehicle by coupling a modular suspension frame to the chassis, in accordance with an
embodiment.
DETAILED DESCRIPTION
[017] Exemplary embodiments are described with reference to the accompanying
drawings. Wherever convenient, the same reference numbers are used throughout the
drawings to refer to the same or like parts. While examples and features of disclosed
principles are described herein, modifications, adaptations, and other implementations are
possible without departing from the spirit and scope of the disclosed embodiments. It is
intended that the following detailed description be considered as exemplary only, with the
true scope and spirit being indicated by the following claims. Additional illustrative
embodiments are listed below.
[018] A modular suspension frame is disclosed that is configured to be coupled
with a chassis of a vehicle using fasteners. As such, the modular suspension frame is
introduced in the load flow path or the complete assembly of a suspension system of the
vehicle. Optimum load paths are defined and consequently hard points are placed at
optimal locations on the chassis by employing rigorous analytical and computational
techniques, by virtue of which weight reduction is also achieved. Load sensors are placed
on the hard points to finally validate the analytical and computational results. Structurally
optimized members are placed in the modular suspension frame for further weight
reduction of the modular suspension frame while meeting stringent requirements for
stiffness.
[019] The modular suspension frame keeps the roll gradient of the vehicle in
cornering maneuvers minimum. Due to availability of large packaging space, optimum
6
suspension geometry i.e. distance between Center of Gravity (COG) and the vehicle roll
center, lower and upper A-arms’ (i.e. wishbone arms) angles are achieved. This orientation
has a beneficial effect on ground clearance of the vehicle which is increased significantly.
This modular suspension frame is jointed to chassis side members using bolts and L-cross
sectional members which also incorporate shocker mounts. The modular suspension frame
may include mounting brackets for A-arms and damper strut, suspension assembly,
steering knuckle, upper lower arm, ball joint, damper and spring strut and anti-roll bar,
wheel assembly-hub, bearing, tire, wheel, etc.
[020] The modular suspension frame is manufactured using aluminum alloy,
which provides for weight-reduction of the suspension system and of the overall vehicle.
The modular suspension frame allows to accommodate the complete suspension assembly
and the components of the steering assembly (i.e. track rods and tie rods). This adds to the
modularity of the steering system as well. Further, the modular suspension frame is
coupled to the chassis using fasteners, such as bolts, instead of welded joints. This
provides for easy and quick assembling and disassembling, and therefore, convenient
repairing, servicing, maintenance, and manufacturing of suspension and steering systems.
The modular suspension frame can be replaced in any vehicle upon failure of any
component in the complete assembly so that number of vehicles in the fleet remain
constant and pre-scheduled operations do not get hampered.
[021] Referring to FIG. 1A, a perspective view of a modular suspension frame
100 is illustrated, in accordance with an embodiment of the present disclosure. In some
embodiments, the modular suspension frame 100 may be configured to be coupled to a
chassis (not shown in the FIG. 1) of a vehicle (not shown in the FIG. 1), for example,
using fasteners. In other words, the modular suspension frame 100 may detachable from
the chassis of the vehicle.
[022] In some embodiments, the modular suspension frame 100 may include a
base 102 having a left end 102A and a right end 102B. in other words, the left end 102A
and the right end 102B may define a left extremity and a right extremity, respectively, of
the base 102. The modular suspension frame 100 may further include a left-side body 104
positioned on the left end 102A of the base 102, and a right-side body 110 positioned on
7
the right end 102B of the base 102. The modular suspension frame 100 may further
include a left mounting arm 116 coupled to the left-side body 104, and a right mounting
arm 118 coupled to the right-side body 110. It may be noted that the modular suspension
frame 100 may be configured to be coupled with the chassis of the vehicle, via the left
mounting arm 116 and the right mounting arm 118 using a plurality of fasteners.
[023] In some embodiments, the left-side body 104 may include a bend. For
example, the left-side body 104 may include a left lower segment 104A and a left upper
segment 104B. The left lower segment 104A and the left upper segment 104B may be
inclined at the first predefined angle, so as to introduce the bend in the left-side body 104.
Similarly, the right-side body 110 may include a bend. For example, the right-side body
110 may include a right lower segment 110A and a right upper segment 110B. The right
lower segment 110A and the right upper segment 110B may be inclined at the first
predefined angle, so as to introduce the bend in the left-side body 104.
[024] Referring now to FIG. 2A, another perspective view of the modular
suspension frame 100 is illustrated, in accordance with an embodiment of the present
disclosure. In some embodiments, the base 102 may include at least two longitudinal
members, for example, a longitudinal member 120A and a longitudinal members 120B,
extending between the left end 102A and the right end 102B of the base 102. The base 102
may further include a left lateral member 122A positioned on each of the at least two
longitudinal members 120A, 120B towards the left end 102A of the base 102. The base
102 may further include a right lateral member 122B. The right lateral member 122B may
be positioned on the two longitudinal members 120A, 120B towards the right end 102B of
the base 102.
[025] In some embodiments, each of the longitudinal members 120A, 120B, the
left lateral member 122A, and the right lateral member 122B may be tubular-shaped
having a rectangular cross-section. Further, in some embodiments, the left lateral member
122A and the right lateral member 122B may be fitted to each of the longitudinal members
120A, 120B, for example, by way of welding or using one or more fasteners. In alternate
embodiments, the left lateral member 122A and the right lateral member 122B may be
formed into the longitudinal members 120A, 120B as a single piece.
8
[026] As mentioned earlier, the modular suspension frame 100 may further
include a left-side body 104 positioned on the left end 102A of the base 102. In some
embodiments, the left-side body 104 may include a first left-side member 106. The first
left-side member 106 may include a first left-side lower segment 106A and a first left-side
upper segment 106B. The first left-side lower segment 106A may be inclined to the first
left-side upper segment 106B at a first predefined angle. In some embodiments, the first
left-side member 106 may be formed as single piece having the first left-side lower
segment 106A and the first left-side upper segment 106B. In alternate embodiments, the
first left-side lower segment 106A and the first left-side upper segment 106B may be
individual parts which may be fitted together, for example, by welding, to generate the
first left-side member 106.
[027] The modular suspension frame 100 may further include a second left-side
member 108. The second left-side member 108 may include a second left-side lower
segment 108A and a second left-side upper segment 108B. The second left-side lower
segment 108A may be inclined to the second left-side upper segment 108B at the first
predefined angle. Similar to the first left-side member 106, in some embodiments, the
second left-side member 108 may be formed as single piece having the first left-side lower
segment 108A and the second left-side upper segment 108B. In alternate embodiments, the
second left-side lower segment 108A and the second left-side upper segment 108B may be
individual parts which may be fitted together, for example, by welding, to generate the
second left-side member 108.
[028] It may be further noted that, in some embodiments, the angle of inclination
between the first left-side lower segment 106A and the first left-side upper segment 106B
and the angle of inclination between the second left-side lower segment 108A and the
second left-side upper segment 108B may be same, i.e. the first predefined angle.
However, in alternate embodiments, the two angles of inclination (i.e. the angle of
inclination between the first left-side lower segment 106A and the first left-side upper
segment 106B and the angle of inclination between the second left-side lower segment
108A and the second left-side upper segment 108B) may be different.
9
[029] The modular suspension frame 100 may further include a right-side body
110 positioned on the right end 102B of the base 102. In some embodiments, the right-side
body 110 may include a first right-side member 112. The first right-side member 112 may
include a first right-side lower segment 112A and a first right-side upper segment 112B.
The first right-side lower segment 112A may be inclined to the first right-side upper
segment 112B at a second predefined angle. In some embodiments, the first right-side
member 112 may be formed as single piece having the first right-side lower segment 112A
and the first right-side upper segment 112B. In alternate embodiments, the first right-side
lower segment 112A and the first right-side upper segment 112B may be individual parts
which may be fitted together, for example, by welding, to generate the first right-side
member 112.
[030] The modular suspension frame 100 may further include a second right-side
member 114. The second right-side member 114 may include a second right-side lower
segment 114A and a second right-side upper segment 114B. The second right-side lower
segment 114A may be inclined to the second right-side upper segment 114B at the second
predefined angle. Similar to the first right-side member 112, the second right-side member
114 may be formed as single piece having the second right-side lower segment 114A and
the second right-side upper segment 114B. In alternate embodiments, the second right-side
lower segment 114A and the second right-side upper segment 114B may be individual
parts which may be fitted together, for example, by welding, to generate the second rightside member 114.
[031] It may be further noted that, in some embodiments, the angle of inclination
between the first right-side lower segment 112A and the first right-side upper segment
112B and the angle of inclination between the second right-side lower segment 114A and
the second right-side upper segment 114B may be same, i.e. the second predefined angle.
However, in alternate embodiments, the two angles of inclination (i.e. the angle of
inclination between the first right-side lower segment 112A and the first right-side upper
segment 112B and the angle of inclination between the second right-side lower segment
114A and the second right-side upper segment 114B) may be different.
10
[032] Further, in some embodiments, the first predefined angle may same as the
second predefined angle. However, in some embodiments, the first predefined angle may
be different from the second predefined angle. This is further explained in detail in
conjunction with FIG. 2B.
[033] FIG. 2B is a schematic diagram of front view of the module suspension
frame 100, in accordance with an embodiment. As shown, in some embodiments, the first
left-side lower segment 106A may be inclined to the first left-side upper segment 106B at
the first predefined angle θ1. The second left-side lower segment 108A may be inclined to
the second left-side upper segment 108B at the first predefined angle θ1. Further, the first
right-side lower segment 112A may be inclined to the first right-side upper segment 112B
at the second predefined angle θ2. The second right-side lower segment 114A may be
inclined to the second right-side upper segment 114B at the second predefined angle θ2. In
some embodiments, the first predefined angle θ1 and the second predefined angle θ2 may
vary within a range of 135 degrees to 180 degrees. Further, in some embodiments, the first
predefined angle θ1 may be equal to the second predefined angle θ2, i.e. θ1 = θ2.
[034] It may be noted that the bends in the left-side body 104 and the right-side
body 110, i.e. the first predefined angle θ1 and the second predefined angle θ2, may
provide for lowering down the roll-center point of the front wheels of the vehicle. This
may add to safety of the vehicle.
[035] In some embodiments, each of the left lateral member 122A and the right
lateral member 122B may be coupled to the longitudinal members 120A, 120B while
being to the longitudinal members 120A, 120B at some predefined angle.
[036] Returning back to FIG. 2A, in some embodiments, the left-side body 104
may be positioned on the left end 102A of the base 102 via the left lateral member 122A.
In other words, the first left-side lower segment 106A of the first left-side member 106 and
the second left-side lower segment 108A of the second left-side member 108 may be
coupled to the left lateral member 122A, for example, via welding or using one or more
fasteners like bolts, or nut-bolt assemblies, or rivets, etc. In alternate embodiments, the
first left-side member 106 and the second left-side member 108 may be formed with the
left lateral member 122A as a single piece.
11
[037] Similarly, the right-side body 110 may be positioned on the right end 102B
of the base 102 via the right lateral member 122B. In other words, the first right-side lower
segment 112A of the first right-side member 112 and the second right-side lower segment
114A of the second right-side member 114 may be coupled to the right lateral member
122B, for example, via welding or using one or more fasteners like bolts, or nut-bolt
assemblies, or rivets, etc. In alternate embodiments, the first right-side member 112 and
the second right-side member 114 may be formed with the right lateral member 122B as a
single piece.
[038] As mentioned earlier, the modular suspension frame 100 may further
include a left mounting arm 116 coupled to the left-side body 104, and a right mounting
arm 118 coupled to the right-side body 110. Each of the left mounting arm 116 and the
right mounting arm 118 may have an L-shaped configuration. For example, the left
mounting arm 116 may include a horizontal plate 116A and a vertical plate 116B, such
that the horizontal plate 116A and a vertical plate 116B may be aligned to form the Lshaped configuration. Similarly, the right mounting arm 118 may include a horizontal
plate 118A and a vertical plate 118B, such that the horizontal plate 118A and the vertical
plate 118B may be aligned to form the L-shaped configuration.
[039] In some embodiments, each of the vertical plate 116B and the vertical plate
118B may include a plurality of holes. It may be noted that the modular suspension frame
100 may be configured to be coupled with the chassis of the vehicle, via the plurality of
holes of the vertical plate 116B and the vertical plate 118B using a plurality of fasteners
(not shown in FIG. 2A). It may be further noted that the fasteners may include bolts, or
nut-bolt assemblies, or rivets, etc.
[040] The left mounting arm 116 and the right mounting arm 118 may provide
for proper connections between the modular suspension frame 100 and the chassis, and
further allow for proper load flow between the modular suspension frame 100 and the
chassis.
[041] In some embodiments, the modular suspension frame 100 may further
include a first left lower clamp 124A, a second left lower clamp 124B, a first left upper
clamp 124C, a second left upper clamp 124D, a first right lower clamp 124E, a second
12
right lower clamp 124F, a first right upper clamp 124G, and a second right upper clamp
124H.
[042] The first left lower clamp 124A and the second left lower clamp 124B may
be positioned on the left lateral member 122A. It may be noted that, in some embodiments,
the first left lower clamp 124A and the second left lower clamp 124B may be fitted to the
left lateral member 122A via welding, or using one or more fasteners like bolts, or nut-bolt
assemblies, or rivets. In alternate embodiments, the first left lower clamp 124A and the
second left lower clamp 124B may be formed into the left lateral member 122A as a single
piece.
[043] Further, the first left upper clamp 124C may be coupled to the first left-side
upper segment 106B of the first left-side member 106, and the second left upper clamp
124D may be coupled to the second left-side upper segment 108B of the second left-side
member 108. Again, in some embodiments, the first left upper clamp 124C may be fitted
to the first left-side upper segment 106B, and the second left upper clamp 124D may be
coupled to the second left-side upper segment 108B, via welding, or using one or more
fasteners like bolts, or nut-bolt assemblies, or rivets. In alternate embodiments, the first
left upper clamp 124C may be formed into the first left-side member 106 as a single piece.
Similarly, the second left upper clamp 124D may be formed into the second left-side
member 108 as a single piece.
[044] Further, the first right lower clamp 124E and the second right lower clamp
124F may be coupled to the right lateral member 122B. Again, the first right lower clamp
124E and the second right lower clamp 124F may be fitted to the right lateral member
122B via welding, or using one or more fasteners like bolts, or nut-bolt assemblies, or
rivets. In alternate embodiments, the first right lower clamp 124E and the second right
lower clamp 124F may be formed into the right lateral member 122B as a single piece.
[045] The first right upper clamp 124G may be coupled to the first right-side
upper segment 112B of the first right-side member 112. The second right upper clamp
124H may be coupled to the second right-side upper segment 114B of the second rightside member 114. To this end, in some embodiments, the first right upper clamp 124G and
the second right upper clamp 124H may be fitted to the first right-side upper segment
13
112B and the second right-side upper segment 114B, respectively, via welding, or using
one or more fasteners like bolts, or nut-bolt assemblies, or rivets. Alternately, the first right
upper clamp 124G and the second right upper clamp 124H may be formed into the first
right-side member 112 and the second right-side upper segment 114B, respectively, as a
single piece.
[046] It may be further noted that a left lower wishbone arm, or simply left lower
arm (not shown in FIG. 2A) may be coupled to the modular suspension frame 100 via the
first left lower clamp 124A and the second left lower clamp 124B. Further, a left upper
arm may be coupled to the modular suspension frame 100 via the first left upper clamp
124C and the second left upper clamp 124D. Furthermore, a right lower arm (not shown in
FIG. 2A) may be coupled to the modular suspension frame 100 via the first right lower
clamp 124E and the second right lower clamp 124F. Moreover, a right upper arm may be
coupled to the modular suspension frame 100 via the first right upper clamp 124G and the
second right upper clamp 124H. This is further explained in detail, in conjunction with
FIGS. 3A-B.
[047] Referring now to FIG. 3A and FIG. 3B, a perspective view of a suspension
system 300 and a magnified view of the suspension system 300, respectively, of a vehicle
are illustrated, in accordance with an embodiment of the present disclosure. The
suspension system 300 may include the modular suspension frame 100. As mentioned, the
modular suspension frame 100 may be configured to be coupled to the chassis of a vehicle.
[048] By way of an example, the suspension system 300 may be a double wishbone type suspension system. As it will be appreciated by those skilled in the art, the
wishbone suspension is an independent suspension system which may use two pairs of
substantially parallel wishbone-shaped arms to locate the wheels of the vehicle. As shown
in FIG. 3A, the suspension system 300 may include a left lower arm 302A, a left upper
arm 302B, and right lower arm 304A and a right upper arm 304B. Each of the left lower
arm 302A, the left upper arm 302B, right lower arm 304A, and the right upper arm 304B
may be coupled to the chassis of the vehicle via respective two first-type mounting points.
Further, each of the left lower arm 302A, the left upper arm 302B, the right lower arm
304A, and the right upper arm 304B may be coupled to a respective knuckle of the vehicle
14
via a respective second-type mounting point. It will be further appreciated that in the
suspension system, a knuckle is the part which contains the wheel hub or spindle, and
attaches to the suspension system and steering components.
[049] As shown in the FIG. 3A, the left lower arm 302A may be coupled to the
modular suspension frame 100 (the modular suspension frame 100 being coupled to the
chassis of the vehicle) via the first left lower clamp 124A and the second left lower clamp
124B (not shown in FIG. 3A-B). As such, the first left lower clamp 124A and the second
left lower clamp 124B act as the first-type mounting points of the left lower arm 302A.
Further, the left upper arm 302B may be coupled to the modular suspension frame 100 via
the first left upper clamp 124C and the second left upper clamp 124D (not shown in FIG.
3A-B). As such, the first left upper clamp 124C and the second left upper clamp 124D act
as the first-type mounting points of the left upper arm 302B.
[050] The right lower arm 304A may be coupled to the modular suspension
frame 100 via the first right lower clamp 124E and the second right lower clamp 124F (not
shown in FIG. 3A-B). As such, the first right lower clamp 124E and the second right lower
clamp 124F act as the first-type mounting points of the right lower arm 304A. Further, the
right upper arm 304B may be coupled to the modular suspension frame 100 via the first
right upper clamp 124G (not shown in FIG. 3A-B) and the second right upper clamp 124H
(not shown in FIG. 3A-B). Therefore, the first right upper clamp 124G and the second
right upper clamp 124H act as the first-type mounting points of the right upper arm 304B.
[051] Referring now to FIG. 3B, a magnified view of the suspension system 300
is illustrated, in accordance with an embodiment. As shown in the FIG. 3B, the suspension
system 300 includes the modular suspension frame 100. Further, the suspension system
300 includes the right lower arm 304A and the right upper arm 304B. As mentioned
earlier, the right lower arm 304A may be coupled to the modular suspension frame 100 via
the first right lower clamp 124E and the second right lower clamp 124F through its one
end. The right lower arm 304A may be coupled to the knuckle, through the other end (via
the second-type mounting point).
[052] The suspension system 300 may further include a left shock-absorber
assembly 306A (not shown in FIG. 3B) and a right shock-absorber assembly 306B. In
15
some embodiments, each of the left shock-absorber assembly 306A and the right shockabsorber assembly 306B may be of spring over damper configuration. The spring over
damper configuration may include a spring component and a damper component, the
spring component being positioned over the damper component, i.e. the spring component
being wrapped around the damper component.
[053] As shown in the FIG. 3B, in some embodiments, the right shock-absorber
assembly 306B may be coupled to the right lower arm 304A through a first end of the
right shock-absorber assembly 306B. The right shock-absorber assembly 306B may
further be coupled to the modular suspension frame 100 though a second end of the right
shock-absorber assembly 306B. In such embodiments, the right shock-absorber assembly
306B may pass through the right upper arm 304B while being coupled to the right lower
arm 304A and the modular suspension frame 100. In other words, the left and the right
upper arms 302B, 304B may provide passage to the left and the right shock-absorber
assemblies 306A, 306B, respectively.
[054] In some embodiments, the left mounting arm 116 and the right mounting
arm 118 may include a left backward projection 308A (not shown in FIG. 3B) and a right
backward projection 308B, respectively. It may be noted that the left backward projection
308A and the right backward projection 308B may be fitted to the left mounting arm 116
and the right mounting arm 118, respectively, via welding, or using one or more bolts, or
one or more not-bolt assemblies, etc. Alternatively, the left backward projection 308A and
the right backward projection 308B may be formed in to left mounting arm 116 and the
right mounting arm 118, respectively, as individual pieces.
[055] In such embodiments, the left shock-absorber assembly 306A and the right
shock-absorber assembly 306B may be coupled to the modular suspension frame 100 via
the left backward projection 308A and the right backward projection 308B, respectively.
For example, as shown in FIG. 3B, the right shock-absorber assembly 306B is coupled to
the modular suspension frame 100 via the right backward projection 308B.
[056] In some embodiments, the modular suspension frame 100 may be
manufactured using an Aluminum alloy. In particular, each of the first left-side member
106, the second left-side member 108, the first right-side member 112, the second right-
16
side member 114, the at least two longitudinal members 120A, 120B, the left lateral
member 122A, and the right lateral member 122B (each being tubular-shaped having a
rectangular cross-section) may be made of the Aluminum alloy. It may be understood that
by way of using the Aluminum alloy, weight reduction of the modular suspension frame
100 and, therefore, of the overall vehicle may be achieved.
[057] Referring now to FIG. 4A-C, different perspective views of a vehicle 400
implementing the modular suspension frame 100 are illustrated, in accordance with some
embodiments of the present disclosure. By way of one example, the vehicle 400 may be a
light commercial electric vehicle. However, in other examples, the vehicle 400 may be any
other kind of electric vehicle or internal combustion-engine based vehicle as well.
[058] As shown in FIG. 4A, the vehicle 400 may include a chassis 402. The
modular suspension frame 100 may be configured to be coupled to the chassis 402. As
mentioned above, the modular suspension frame 100 may be configured to be coupled
with the chassis 402 of the vehicle 400, via the left mounting arm 116 and the right
mounting arm 118 using the plurality of fasteners. Further, the plurality of fasteners may
include bolts, or not-bolt assemblies, or rivets.
[059] As mentioned above in conjunction with FIG. 1 and FIG. 2A-B, the
modular suspension frame 100 may include the base 102 having the left end 102A and the
right end 102B. The modular suspension frame 100 may further include the left-side body
104 positioned on the left end 102A of the base 102. The left-side body 104 may include a
bend. For example, the left-side body 104 may include a left lower segment 104A and a
left upper segment 104B. The left lower segment 104A and the left upper segment 104B
may be inclined at the first predefined angle, so as to introduce the bend in the left-side
body 104. Similarly, the right-side body 110 may include a bend. For example, the rightside body 110 may include a right lower segment 110A and a right upper segment 110B.
The right lower segment 110A and the right upper segment 110B may be inclined at the
first predefined angle, so as to introduce the bend in the left-side body 104.
[060] FIG. 4B and FIG. 4C show some more perspective views of the vehicle
400 implementing the modular suspension frame 100 are illustrated, in accordance with
some embodiments of the present disclosure.
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[061] Referring now to FIG. 5, a method 500 of assembling a suspension system
300 of vehicle by coupling a modular suspension frame 100 to the chassis 402 is disclosed,
in accordance with an embodiment of the present disclosure. At step 502, the modular
suspension frame 100 may be manufactured. The manufacturing of the modular
suspension frame 100 may include cutting one or more tubular-shaped member having a
rectangular cross-section into multiple members having predetermined shapes, for
example, using a Computer Numerical Controlled machine. The manufacturing may
further include joining the multiple members to generate the modular suspension frame
100. It may be noted that the manufacturing of the modular suspension frame 100 may
include convenient placement of the chassis hardpoints for optimum load path transfer and
light weighting, and achieving optimum load flow path by employing rigorous engineering
design and analysis.
[062] At step 504, the modular suspension frame 100 may be coupled to the
chassis 402 of the vehicle 400, using the plurality of fasteners. In some embodiments, first,
the left mounting arm 116 may be coupled to the left-side body 104 of the modular
suspension frame 100 and the right mounting arm 118 may be coupled to the right-side
body 110 of the modular suspension frame 100. Thereafter, the left mounting arm 116 and
the right mounting arm 118 may be coupled to the chassis 402 of the vehicle 400, using
the plurality of fasteners.
[063] At step 506, various components of the suspension system 300, for
example, wishbone arms, shock-absorber assemblies, etc. may be coupled to the modular
suspension frame 100. At step 508, these various components of the suspension system
300 may be further coupled to the respective components of the vehicle 400. For example,
wishbone arms may be further coupled to the knuckles, and the shock-absorber assemblies
may be further coupled to the wishbone arms. At step 510, various components of the
steering system may be coupled to the respective components of the vehicle 400. For
example, the various components of the steering system may include knuckles, A-arms,
steering links, etc.
[064] A modular suspension frame for coupling with a chassis of a vehicle is
disclosed. The modular suspension frame is subject to various shearing and bending
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stresses which may compromise the strength of various joints associated with the modular
suspension frame. However, by way of coupling the modular suspension frame to the
chassis of the vehicle using fasteners instead of welding, this compromise in the strength
of joints (due to welding) is avoided. Moreover, Aluminum alloy-based modular
suspension frame provides a high strength-to-weight ratio and mechanical properties
which provides an added advantage of increased mileage or kms/full charge (for electric
vehicles). Further, modular suspension frame can be made universal i.e. it can be
assembled and retrofitted in different vehicles with weight and spatial variations.
Furthermore, by achieving optimum load flow path by employing rigorous engineering
design and analysis techniques in the design phase, better accidental protection is assured
in case of vehicle impact. Moreover, the modular suspension frame makes placement of
the chassis hardpoints convenient for optimum load path transfer and light weighting.
[065] The terminology used herein is for the purpose of describing particular
embodiments only and is not intended to be limiting of the disclosure. It will be
appreciated that several of the above-disclosed and other features and functions, or
alternatives thereof, may be combined into other systems or applications. Various
presently unforeseen or unanticipated alternatives, modifications, variations, or
improvements therein may subsequently be made by those skilled in the art without
departing from the scope of the present disclosure as encompassed by the following
claims.
[066] The claims, as originally presented and as they may be amended,
encompass variations, alternatives, modifications, improvements, equivalents, and
substantial equivalents of the embodiments and teachings disclosed herein, including those
that are presently unforeseen or unappreciated, and that, for example, may arise from
applicants/patentees and others.
[067] It will be appreciated that variants of the above-disclosed and other
features and functions, or alternatives thereof, may be combined into many other different
systems or applications. Various presently unforeseen or unanticipated alternatives,
modifications, variations, or improvements therein may be subsequently made by those
skilled in the art which are also intended to be encompassed by the following claims.

We claim:

1. A modular suspension frame (100) for coupling with a chassis (402) of a vehicle (400),
the modular suspension frame (100) comprising:
a base (102) having a left end (102A) and a right end (102B);
a left-side body (104) positioned on the left end (102A) of the base (102),
wherein the left-side body (104) comprises:
a first left-side member (106) comprising a first left-side lower segment
(106A) and a first left-side upper segment (106B), wherein the first left-side
lower segment (106A) is inclined to the first left-side upper segment (106B) at a
first predefined angle;
a second left-side member (108) comprising a second left-side lower
segment (108A) and a second left-side upper segment (108B), wherein the
second left-side lower segment (108A) is inclined to the second left-side upper
segment (108B) at the first predefined angle;
a right-side body (110) positioned on the right end (102B) of the base (102),
wherein the right-side body (110) comprises:
a first right-side member (112) comprising a first right-side lower
segment (112A) and a first right-side upper segment (112B), wherein the first
right-side lower segment (112A) is inclined to the first right-side upper segment
(112B) at a second predefined angle;
a second right-side member (114) comprising a second right-side lower
segment (114A) and a second right-side upper segment (114B), wherein the
second right-side lower segment (114A) is inclined to the second right-side upper
segment (114B) at the second predefined angle;
a left mounting arm (116) coupled to the left-side body (104); and
a right mounting arm (118) coupled to the right-side body (110),
wherein the modular suspension frame (100) is configured to be coupled
with the chassis (402) of the vehicle (400), via the left mounting arm (116) and
the right mounting arm (118) using a plurality of fasteners.
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2. The modular suspension frame (100) as claimed in claim 1, wherein each of the left
mounting arm (116) and the right mounting arm (118) has an L-shaped configuration
having a horizontal plate (116A, 118A) and a vertical plate (116B, 118B), wherein each of
the vertical plates (116B, 118B) comprises a plurality of holes, and wherein the modular
suspension frame (100) is configured to be coupled with the chassis (402) of the vehicle
(400), via the plurality of holes of the vertical plates (116B, 118B) using the plurality of
fasteners.
3. The modular suspension frame (100) as claimed in claim 1, wherein the base (102)
comprises:
at least two longitudinal members (120A, 120B), extending between the left end
(102A) and the right end (102B) of the base (102);
a left lateral member (122A) positioned on each of the at least two longitudinal
members (120A, 120B) towards the left end (102A) of the base (102); and
a right lateral member (122B) positioned on each of the at least two longitudinal
members (120A, 120B) towards the right end (102B) of the base (102).
4. The modular suspension frame (100) as claimed in claim 3, wherein the left-side body
(104) is positioned on the left end (102A) of the base (102) via the left lateral member
(122A), and wherein the right-side body (110) is positioned on the right end (102B) of the
base (102) via the right lateral member (122B).
5. The modular suspension frame (100) as claimed in claim 3, wherein each of the first
left-side member (106), the second left-side member (108), the first right-side member
(112), the second right-side member (114), the at least two longitudinal members (120A,
120B), the left lateral member (122A), and the right lateral member (122B) is tubularshaped having a rectangular cross-section.
6. The modular suspension frame (100) as claimed in claim 1, further comprising a first
left lower clamp (124A), a second left lower clamp (124B), a first left upper clamp
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(124C), a second left upper clamp (124D), a first right lower clamp (124E), a second right
lower clamp (124F), a first right upper clamp (124G), and a second right upper clamp
(124H),
wherein the first left lower clamp (124A) and the second left lower clamp (124B)
are positioned on the left lateral member (122A),
wherein the first left upper clamp (124C) and the second left upper clamp (124D)
are positioned on the first left-side upper segment (106B) of the first left-side member
(106) and the second left-side upper segment (108B) of the second left-side member (108),
respectively,
wherein the first right lower clamp (124E) and the second right lower clamp
(124F) are coupled to the right lateral member (122B), and
wherein the first right upper clamp (124G) and the second right upper clamp
(124H) are coupled to the first right-side upper segment (112B) of the first right-side
member (112) and the second right-side upper segment (114B) of the second right-side
member (114), respectively.
7. The modular suspension frame (100) as claimed in claim 6,
wherein a lower arm of a left wishbone is coupled to the modular suspension
frame (100) via the first left lower clamp (124A) and the second left lower clamp (124B),
wherein an upper arm of the left wishbone is coupled to the modular suspension
frame (100) via the first left upper clamp (124C) and the second left upper clamp (124D),
wherein a lower arm of a right wishbone is coupled to the modular suspension
frame (100) via the first right lower clamp (124E) and the second right lower clamp
(124F), and
wherein an upper arm of the right wishbone is coupled to the modular suspension
frame (100) via the first right upper clamp (124G) and the second right upper clamp
(124H).
8. A vehicle (400) comprising:
a chassis (402); and
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a modular suspension frame (100) configured to be coupled with the chassis
(402), the modular suspension frame (100) comprising:
a base (102) having a left end (102A) and a right end (102B);
a left-side body (104) positioned on the left end (102A) of the base
(102), wherein the left-side body (104) comprises a bend with a first predefined
angle;
a right-side body (110) positioned on the right end (102B) of the base
(102), wherein the right-side body (110) comprises a bend with the first
predefined angle; and
a left mounting arm (116) coupled to the left-side body (104); and
a right mounting arm (118) coupled to the right-side body (110),
wherein the modular suspension frame (100) is configured to be coupled
with the chassis (402) of the vehicle (400), via the left mounting arm (116) and
the right mounting arm (118) using a plurality of fasteners.
9. The vehicle (400) as claimed in claim 8,
wherein the base (102) comprises:
at least two longitudinal members (120A, 120B), extending between the
left end (102A) and the right end (102B) of the base (102);
a left lateral member (122A) positioned on each of the at least two
longitudinal members (120A, 120B) towards the left end (102A) of the base
(102); and
a right lateral member (122B) positioned on each of the at least two
longitudinal members (120A, 120B) towards the right end (102B) of the base
(102),
wherein the left-side body (104) comprises:
a first left-side member (106) comprising a first left-side lower segment
(106A) and a first left-side upper segment (106B), wherein the first left-side
lower segment (106A) is inclined to the first left-side upper segment (106B) at a
first predefined angle;
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a second left-side member (108) comprising a second left-side lower
segment (108A) and a second left-side upper segment (108B), wherein the
second left-side lower segment (108A) is inclined to the second left-side upper
segment (108B) at the first predefined angle; and
wherein the right-side body (110) comprises:
a first right-side member (112) comprising a first right-side lower
segment (112A) and a first right-side upper segment (112B), wherein the first
right-side lower segment (112A) is inclined to the first right-side upper segment
(112B) at a second predefined angle; and
a second right-side member (114) comprising a second right-side lower
segment (114A) and a second right-side upper segment (114B), wherein the
second right-side lower segment (114A) is inclined to the second right-side upper
segment (114B) at the second predefined angle.
10. The vehicle (400) as claimed in claim 8 further comprises a left and a right springover-damper shock absorber (306A, 306B), each having a first end and a second end,
wherein the first end of each of the left and the right spring-over-damper shock absorbers
(306A, 306B) is coupled with the modular suspension frame (100), and the second end of
each of the left and the right spring-over-damper shock absorbers (306A, 306B) is coupled
with the left lower arm 302A and the right lower arm 302B, respectively, of a suspension
system of the vehicle (400).