DESC:SUSPENSION FRAME STRUCTURE WITH TORQUE ROD CAVITY
TECHNICAL FIELD
[0001] The present disclosure, in general, relates to a suspension frame structure for a vehicle, and in particularly, a suspension frame structure having a torque rod cavity at center with increased stiffness and improved durability performance of the suspension frame.
BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Generally, the suspension frame is made in bow shape structure and comprises two lower suspension arm attached to both side of the suspension frame. The suspension frame is assembled to the vehicle body. The suspension frame receives suspension arms at both side, an engine mounting member through a torque rod at middle, stabilizer bar, and rack and pinion along with other components.
[0004] As shown in fig. 1a and 1b, the existing suspension frame structure 100 is made of two single sheet material, such as upper plate 101 and lower plate 102 that are joined along the peripheral edge to form the suspension frame structure 100. In between the upper plate 101 and the lower plate 102, a plurality of reinforcements is provided to strengthen the suspension frame structure. The suspension frame structure 100 comprises a central portion along width of the vehicle and a pair of suspension lower arm provided at extreme left and right end side of the central portion. A torque rod 104 is provided at width wise center of the suspension frame structure to mount an engine mount. The suspension frame structure 100 defines a cavity 103, i.e., torque rod cavity 103 at width wise center to receive the torque rod 104 from end from where the pair of suspension lower arm is provided. At one end, the torque rod 104 is connected to the suspension frame 100 and other end is connected with the engine mount.
[0005] Technical problem: The cavity 103 is provided by removing or cutting material from the suspension frame at wall which results in generation of high stress zones as indicated by 103a along high stress lines AA and BB. With these high stress zones 103a, there is high possibility that the suspension frame structure cracks down from these zones. During vehicle running conditions, the cavity 103 receives longitudinal loads from the engine mounting during roll movement of engine and vehicle braking conditions and torsional loads from the wheel while vehicle is negotiating a sharp turn.
[0006] Accordingly, there is a need for suspension frame structure to have a rigid structure for the torque rod cavity to cater torsional loads as well as longitudinal loads.
OBJECTS OF THE DISCLOSURE
[0007] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed hereinbelow.
[0008] It is a general object of the present disclosure to provide a suspension frame structure with increased rigidity of torque rod cavity to cater torsional and longitudinal loads.
[0009] It is another object of the present disclosure to increase rigidity and strength of the suspension frame structure by providing a three box shaped suspension frame structure.
[0010] It is another object of the present disclosure to increase stiffness of the torque rod cavity, thereby reducing strain development along plane of twisting which in turn reduces stress generation.
[0011] It is another object of the present disclosure to provide a crest and trough profile helps in smooth redistribution of stresses near the critical zone.
[0012] It is another object of the present disclosure is to increase stiffness of the torque rod cavity without addition of any part and without increasing weight of the suspension frame structure.
[0013] It is another object of the present disclosure is to increase stiffness of the torque rod cavity without increasing thickness of sheet metal of the upper plate and lower plate.
[0014] These and other objects and advantages of the present invention will be apparent to those skilled in the art after a consideration of the following detailed description taken in conjunction with the accompanying drawings in which a preferred form of the present invention is illustrated.
SUMMARY
[0015] This summary is provided to introduce concepts related to a suspension frame structure with torque rod cavity having stiffness to cater all twisting and longitudinal loads in a vehicle. 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] In an embodiment, the present disclosure relates to a main body of a suspension frame structure comprising a torque rod cavity formed at width wise center of the suspension frame structure. The torque rod cavity defines a rectangular shape and defines two upper corners with a wave shaped profile. The torque rod cavity defines two lower corners along a lap joint formed, in plane of torque rod cavity, between peripheral edges of an upper plate and a lower plate of the main body.

[0017] In an aspect, the torque rod cavity has a lower edge of the lower plate defines a flange extending forward from the torque rod cavity.
[0018] In an aspect, the wave shaped profiled is a combination of crest region formed in between a first trough region and a second trough region. Further, curved edges of the first and second trough regions define respective circles (C1, C3) with center lie toward center of the torque rod cavity. Furthermore, curved edge of the crest region defines a circle (C2) with its center lies away from the center of the torque rod cavity and provided on a solid surface of the main body.
[0019] In an aspect, ratio of radius (R1, R2, R3) of the circles (C1, C2, C3) of the first trough region, the crest region, the second trough region is in range 4 to 6:2 to 4: 5 to 7, respectively.
[0020] In an aspect, the suspension frame structure is a box shaped type suspension frame structure comprises a main body, a right side-body member, and a left side-body member.
[0021] 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.
[0022] It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined to form a further embodiment of the disclosure.
[0023] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, serve to explain the disclosed principles. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system and/or methods in accordance with embodiments of the present subject matter are now described, by way of example only, and with reference to the accompanying figures, in which:
[0025] FIG. 1a, 1b, and 1c illustrate suspension frame structure with torque rod cavity as known in the art;
[0026] Fig. 2a and 2b illustrates a three box shaped suspension frame structure;
[0027] Fig. 2c illustrates a torque rod cavity in the three box shaped suspension frame structure with a flange provided on the lower plate;
[0028] FIG. 3 illustrates a torque rod cavity with wave shaped profile, in accordance with an embodiment of the present disclosure; and
[0029] FIG. 4 illustrates the wave shaped profile of the torque rod cavity with three circles, in accordance with an embodiment of the present disclosure.
[0030] It should be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative systems embodying the principles of the present subject matter.
DETAILED DESCRIPTION
[0031] The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein 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.
[0032] It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
[0033] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a",” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and/or “including,” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
[0034] It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
[0035] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
[0036] As shown in the fig. 2, considering directions from center of the suspension frame structure 100, arrow X1-X2 indicates longitudinal (along vehicle length) direction where X1 indicates forward direction and X2 indicates rearward direction, arrow Y1-Y2 indicates lateral (along vehicle width) direction where Y1 indicates right side and Y2 indicates left side, arrow Z1-Z2 indicates vertical (along vehicle height) direction where Z1 indicates upward direction and Z2 indicates downward direction.
[0037] FIG. 2 illustrates top view of a three box shaped suspension frame structure 100. As shown in FIG. 2, the three box shaped suspension frame structure 100 comprises a main body 101, a right side-body member 102, and a left side-body member 103 where the right side-body member 102 and the left side-body member 103 are attached with the main body 101 at right side and at left side, respectively, along lateral direction or along vehicle width direction to form the suspension frame structure 100.
[0038] The right side-body member 102 and the left side-body member 103 are joined with the main body 101 by various joining methods, such as arc welding or gas welding. The main body 101 with the right side-body member 102 and the left side-body member 103 forms a substantially closed curved surface.
[0039] As shown in fig. 2b and 2c, the main body 200 defines an engine mount receiving structure 203, i.e., torque rod cavity at center to support engine mounting. The central portion of the main body 100 may have higher thickness in vertical direction ‘Z1-Z2’ as compared to thickness on left and right side of the central portion.
[0040] As shown in the fig. 3, the main body 200 (same as 101 of the fig. 2a) of the box type suspension frame structure 100 has upper plate 201 and lower plate 202. Further, a torque rod cavity 203 is defined at width wise center of the main body 200 of the box type suspension frame structure 100 to receive the torque rod such that the torque rod can be connected with the box type suspension frame structure 100 at one end. The torque rod cavity 203 is defined in rectangular shape. In the present disclosure, design and shape of the torque rod cavity 203 is provided to cater high stress in the critical regions of the existing torque rod cavity. These high stress regions are generated along line AA and BB as a result of suspension frame twisting during turning and running of the vehicle.
[0041] To avoid high stresses and to strengthen the weakest section of the torque rod cavity 203, a wave shaped profile 203a is provided at upper two corners of the rectangular shaped torque rod cavity 203. The wave shaped profile 203a is in the form of crest and trough combination. In the present wave shaped profile 203a, one crest is supported by two troughs at each end. The torque rod cavity 203 defines two lower corners along a lap joint formed, in the plane of torque rod cavity 203, between peripheral edges of an upper plate 201 and a lower plate 202 of the box type suspension frame structure 200. The torque rod cavity 203 defines a bow shaped lower edge, which also gives additional strength to the cavity.
[0042] As shown in the fig. 2c, 3, and 4, the lower plate 202 defines a flange 202a that provides strength to the torque rod cavity 203 to handle high stress. The flange 202a extend forward from the torque rod cavity 203 along longitudinal direction X1. The flange 202a reduces stress on trim of the torque rod cavity 203.
[0043] The torque rod cavity 203 defines two lower corners along a lap joint formed, in the plane of torque rod cavity 203, between peripheral edges of an upper plate 201 and a lower plate 202 of the suspension frame structure 200. The torque rod cavity 203 defines a bow shaped lower edge, which also gives additional strength as the lap joint makes a weaker section and this bow shape (flange) leads to bearing more additional twisting load.
[0044] Referring to fig. 3, the crest region is shown by the circle ‘C2’ with radius ‘R2’ and two trough regions are shown by the circle ‘C1’ and ‘C3’ with radius ‘R1’ and ‘R2’, respectively. These circles ‘C1’, ‘C2’, and ‘C3’ are defined by the curved edges of the wave shaped profile 203a. The curved edges of the trough region define the circles ‘C1’ and ‘C3’ with center lie toward center of the torque rod cavity 203. Whereas the curved edge of the crest region defines the circle ‘C2’ with center lies away from the center of the torque rod cavity 203 and defined on solid surface of the suspension frame structure 200.
[0045] In an aspect of the present disclosure, the ratio of radius of R1:R2:R3 is in range 4 to 6:2 to 4: 5 to 7, preferably, 5:3:6 respectively.
[0046] With the present wave shaped profile 203 at upper two corners of the rectangular shape torque rod cavity 203, the following technical advantages are obtained.
[0047] It increases stiffness of weaker section, thereby reducing strain development along plane of twisting which in turn reduces stress generation.
[0048] Crest and trough profile helps in smooth redistribution of stresses near the critical zone. Thus avoiding any stress concentration in the region.
[0049] This profile helps in addressing the issue of high stress without increasing the suspension frame panel thickness and without addition of any reinforcement.
[0050] During assembly of torque rod with suspension frame, this design helps in easier insertion of torque rod without damaging suspension frame.
[0051] While the foregoing 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 main body (200) of a suspension frame structure (100) comprising:
a torque rod cavity (203) formed at width wise center of the suspension frame structure, the torque rod cavity (203) defines a rectangular shape;
characterized in that
the torque rod cavity (203) defines two upper corners with a wave shaped profile (203a), and
the torque rod cavity (203) defines two lower corners along a lap joint formed, in plane of torque rod cavity (203), between peripheral edges of an upper plate (201) and a lower plate (202) of the main body (200).

2. The main body (200) as claimed in claim 1, wherein a lower edge of the lower plate (202) defines a flange (202a) extending forward from the torque rod cavity (203).

3. The main body (200) as claimed in claim 1, wherein the wave shaped profiled (203a) is a combination of crest region formed in between a first trough region and a second trough region.

4. The main body (200) as claimed in claim 3, wherein curved edges of the first and second trough regions define respective circles (C1, C3) with their center lie in the torque rod cavity (203).

5. The main body (200) as claimed in claim 3, wherein curved edge of the crest region defines a circle (C2) with a center lies on a solid surface of the main body (200).

6. The main body (200) as claimed in claim 4 and 5, wherein ratio of radius (R1, R2, R3) of the circles (C1, C2, C3) of the first trough region, the crest region, the second trough region is in range 4 to 6:2 to 4: 5 to 7, respectively.

7. The main body (200) as claimed in claim 1, wherein the suspension frame structure is a box shaped type suspension frame structure comprises a main body (101), a right side-body member (102), and a left side-body member (103).

8. The main body (200) as claimed in claim 7, wherein the right side-body member (102) and the left side-body member (103) joined with the main body (101) at right hand side and left hand side, respectively.