WO2006046876A1 - An aluminium control arm and a method for the production of the same - Google Patents

An aluminium control arm and a method for the production of the same Download PDF

Info

Publication number
WO2006046876A1
WO2006046876A1 PCT/NO2005/000408 NO2005000408W WO2006046876A1 WO 2006046876 A1 WO2006046876 A1 WO 2006046876A1 NO 2005000408 W NO2005000408 W NO 2005000408W WO 2006046876 A1 WO2006046876 A1 WO 2006046876A1
Authority
WO
WIPO (PCT)
Prior art keywords
arm
profile
aluminium
seat
spring unit
Prior art date
Application number
PCT/NO2005/000408
Other languages
French (fr)
Inventor
Trygve Ruste
Original Assignee
Raufoss Technology As
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Raufoss Technology As filed Critical Raufoss Technology As
Priority to DE112005002470.9T priority Critical patent/DE112005002470B4/en
Publication of WO2006046876A1 publication Critical patent/WO2006046876A1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G11/00—Resilient suspensions characterised by arrangement, location or kind of springs
    • B60G11/14—Resilient suspensions characterised by arrangement, location or kind of springs having helical, spiral or coil springs only
    • B60G11/16—Resilient suspensions characterised by arrangement, location or kind of springs having helical, spiral or coil springs only characterised by means specially adapted for attaching the spring to axle or sprung part of the vehicle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G7/00—Pivoted suspension arms; Accessories thereof
    • B60G7/001—Suspension arms, e.g. constructional features
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2204/00—Indexing codes related to suspensions per se or to auxiliary parts
    • B60G2204/10—Mounting of suspension elements
    • B60G2204/12—Mounting of springs or dampers
    • B60G2204/124—Mounting of coil springs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2204/00—Indexing codes related to suspensions per se or to auxiliary parts
    • B60G2204/10—Mounting of suspension elements
    • B60G2204/12—Mounting of springs or dampers
    • B60G2204/124—Mounting of coil springs
    • B60G2204/1244—Mounting of coil springs on a suspension arm
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2206/00—Indexing codes related to the manufacturing of suspensions: constructional features, the materials used, procedures or tools
    • B60G2206/01—Constructional features of suspension elements, e.g. arms, dampers, springs
    • B60G2206/10—Constructional features of arms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2206/00—Indexing codes related to the manufacturing of suspensions: constructional features, the materials used, procedures or tools
    • B60G2206/01—Constructional features of suspension elements, e.g. arms, dampers, springs
    • B60G2206/10—Constructional features of arms
    • B60G2206/11—Constructional features of arms the arm being a radius or track or torque or steering rod or stabiliser end link
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2206/00—Indexing codes related to the manufacturing of suspensions: constructional features, the materials used, procedures or tools
    • B60G2206/01—Constructional features of suspension elements, e.g. arms, dampers, springs
    • B60G2206/70—Materials used in suspensions
    • B60G2206/71—Light weight materials
    • B60G2206/7102—Aluminium alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2206/00—Indexing codes related to the manufacturing of suspensions: constructional features, the materials used, procedures or tools
    • B60G2206/01—Constructional features of suspension elements, e.g. arms, dampers, springs
    • B60G2206/80—Manufacturing procedures
    • B60G2206/81—Shaping
    • B60G2206/8103—Shaping by folding or bending

Definitions

  • the present invention relates to a control arm in the rear wheel suspension in a car, and in particular an elongate rear control arm which is the lower member in a multi link rear wheel suspension, and more particular a lower arm carrying a spring or spring-and-damper unit.
  • Aluminium lends itself particularly well for this application as it is lightweight, corrosion resistant and very ductile.
  • the operation must be performed in an inert atmosphere.
  • the parts that are to be welded together must match each other closely; the maximum allowable gap between the parts is about 0.2 mm. To obtain such close tolerances, the individual parts must be made with great care, possibly involving special techniques such as hydro forming. These factors contribute in making welded aluminium suspension members very expensive.
  • Another object is to produce the arm in a cold process only involving standard external forming methods like cutting, stretch-bending, hole punching, etc.
  • Fig. Ia and Ib shows a prior art control arm in steel with a recess for mounting a spring unit, and the individual components of the arm.
  • Fig. 2 shows in cross section an extruded aluminium profile particularly suited for the production of a control arm according to the present invention.
  • Fig. 3 a - d shows the production of a control arm according to the present invention in five steps.
  • Fig. 4 shows the finished product.
  • Fig. Ib a prior art control arm.
  • the arm is produced from an upper and lower main element illustrated in Fig. Ia.
  • Sheet metal is stamped and pressed into the respective shaped element.
  • the upper element includes an opening intended to accommodate a spring.
  • the lower element includes a corresponding "trough", in which the spring will rest.
  • the elements are subsequently welded together as shown in Fig. Ib. This partly hollow construction is necessary in order to obtain the needed strength. Additional components are welded to the upper and lower element.
  • Fig. 2 is shown a special profile extruded from high strength aluminium.
  • the profile includes two side channels 1, 2 which are closed in cross section.
  • the channels 1, 2 are connected by a broad bridge 3.
  • the bridge 3 should be made wide enough to hold the lower end of the spring, i.e. it will define the maximum width of the spring seat.
  • the bridge 3 is placed between the lower extremities of the channels 1, 2.
  • the bridge may as well be located e.g. at the middle of the side channels forming a binocular-like profile. The important point is to use a profile with channels and connecting bridge extruded as a single piece.
  • the arm is produced in a five step process illustrated in Fig. 3 a-e.
  • Fig. 3a shows the first step in the production process.
  • An appropriate straight length of aluminium profile is cut from stock profile.
  • the profile is bent into an arc while- stretched to avoid wrinkles at the inside of the arc. Then the length of aluminium profile is cut into two pieces along the mid line.
  • step c the profile is pressed together at the ends.
  • step d the spring seat is formed by pressing and forming a hole.
  • the shapes of the ends are adjusted by cutting away superfluous material.
  • a fork is formed at the left hand end.
  • step e The process is completed in step e by forming mounting holes at the ends . Bushings will later be set into the holes.
  • the production process is essentially finished, as there is no need for additional finishing steps, such as hardening, painting or anti-corrosion treatment.
  • the process is very compact involving only cold processing steps, i.e. no welding or forging. It is a simple process that may be executed with standard workshop tools.
  • the result of the process described above is a control arm as depicted in Fig. 4.
  • the arm includes a seat 42 for a spring unit, located in a lower bridge 41.
  • the seat is thus located in a recess surrounded by reinforcing channels 43, 44.
  • Bushings are inserted in mounting holes 45, 46 at the ends of the arm.
  • an arm produced by this inventive method will have a lowered mounting seat for the spring.
  • it will have similar strength properties, mainly due to the two reinforcing channels.
  • the weight will typically be reduced with more than 50%.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Vehicle Body Suspensions (AREA)

Abstract

An aluminium control arm for the wheel suspension of a vehicle is described. The arm is a rear lower arm for a multilink suspension, and is featuring a recessed mounting seat for a spring unit. The arm is produced from a specially designed aluminium profile with a lower bridge defining the spring mounting seat, and with narrow side channels giving strength to the arm.

Description

AN ALUMINIUM CONTROL ARM AND A METHOD FOR THE PRODUCTION OP THE SAME
Field of the invention
The present invention relates to a control arm in the rear wheel suspension in a car, and in particular an elongate rear control arm which is the lower member in a multi link rear wheel suspension, and more particular a lower arm carrying a spring or spring-and-damper unit.
Prior art
Nowadays car producers prefer to replace steel components with corresponding aluminium components in order to keep the weight of the vehicles down. It is particularly important to lighten the weight of the moving parts in the wheel suspension components. Aluminium lends itself particularly well for this application as it is lightweight, corrosion resistant and very ductile.
From the applicant's earlier Norwegian patent application NO 1999 5376 there is known a rear control arm made from an extruded aluminium profile specially designed for the purpose. This control arm has several advantages, of which one is that it can be produced in standard machinery for cold forming, avoiding more involved processes such as welding, hydro forming, etc. While this arm has proved to be a success in the market, it has a disadvantage in that the spring is mounted on the top surface of the arm.
There is known several conventional control arms made from steel in which the spring is mounted in a recess in the arm. This has the advantage that the spring will not protrude so far into the car body, i.e. the upper mounting point can be lowered giving more available room in the luggage compartment. However, this steel component cannot readily be copied in aluminium. Such an arm is produced from several individual pieces of stamped sheet metal welded together. It is not feasible to produce an aluminium arm with this technique due to the welding involved. Welding in aluminium is a delicate process that at length should be avoided, at least when considering serial production.
Large scale production demands the use of welding robots. And automated welding of aluminium is complicated:
The operation must be performed in an inert atmosphere.
The operation will change the material properties in the welding seam, which becomes impaired in strength. In order to obtain the required strength, the material dimensions must be increased, which will make the component heavier. And saving of weight was a motif for using aluminium.
The parts that are to be welded together must match each other closely; the maximum allowable gap between the parts is about 0.2 mm. To obtain such close tolerances, the individual parts must be made with great care, possibly involving special techniques such as hydro forming. These factors contribute in making welded aluminium suspension members very expensive.
There is a challenge to produce suspension members in aluminium to a competitive price, as the material cost is higher compared with steel. The answer to this challenge is to find alternative production methods involving lower cost
Brief summary of the invention
It is an object of the present invention to provide a control arm in aluminium allowing a space saving mounting of a spring or spring-and-damper unit. Another object is to produce said arm by cost effective methods and effectively exploit the properties of aluminium in order to obtain an arm of great strength.
Another object is to produce the arm in a cold process only involving standard external forming methods like cutting, stretch-bending, hole punching, etc.
These objects are achieved in a method for manufacturing a control arm as claimed in claim 1 and an arm as claimed in the appended claim 3.
Brief description of the drawings
The invention will now be described in details in reference to the appended drawings, in which
Fig. Ia and Ib shows a prior art control arm in steel with a recess for mounting a spring unit, and the individual components of the arm.
Fig. 2 shows in cross section an extruded aluminium profile particularly suited for the production of a control arm according to the present invention.
Fig. 3 a - d shows the production of a control arm according to the present invention in five steps.
Fig. 4 shows the finished product.
Detailed description of the invention.
In Fig. Ib is shown a prior art control arm. The arm is produced from an upper and lower main element illustrated in Fig. Ia. Sheet metal is stamped and pressed into the respective shaped element. The upper element includes an opening intended to accommodate a spring. The lower element includes a corresponding "trough", in which the spring will rest. The elements are subsequently welded together as shown in Fig. Ib. This partly hollow construction is necessary in order to obtain the needed strength. Additional components are welded to the upper and lower element.
In Fig. 2 is shown a special profile extruded from high strength aluminium. The profile includes two side channels 1, 2 which are closed in cross section. The channels 1, 2 are connected by a broad bridge 3. The bridge 3 should be made wide enough to hold the lower end of the spring, i.e. it will define the maximum width of the spring seat.
In the figures, the bridge 3 is placed between the lower extremities of the channels 1, 2. However, the bridge may as well be located e.g. at the middle of the side channels forming a binocular-like profile. The important point is to use a profile with channels and connecting bridge extruded as a single piece.
The arm is produced in a five step process illustrated in Fig. 3 a-e.
Fig. 3a shows the first step in the production process. An appropriate straight length of aluminium profile is cut from stock profile. In this case it is preferred to cut a double length, i.e. spanning two arms, as this is advantageous during the subsequent bending process shown in Fig. 3b. The profile is bent into an arc while- stretched to avoid wrinkles at the inside of the arc. Then the length of aluminium profile is cut into two pieces along the mid line.
At step c the profile is pressed together at the ends. In step d the spring seat is formed by pressing and forming a hole. The shapes of the ends are adjusted by cutting away superfluous material. A fork is formed at the left hand end. The process is completed in step e by forming mounting holes at the ends . Bushings will later be set into the holes.
Then, the production process is essentially finished, as there is no need for additional finishing steps, such as hardening, painting or anti-corrosion treatment. The process is very compact involving only cold processing steps, i.e. no welding or forging. It is a simple process that may be executed with standard workshop tools.
The result of the process described above is a control arm as depicted in Fig. 4. The arm includes a seat 42 for a spring unit, located in a lower bridge 41. The seat is thus located in a recess surrounded by reinforcing channels 43, 44. Bushings are inserted in mounting holes 45, 46 at the ends of the arm.
Compared with the prior art aluminium control arm known from NO 1999 5376 A, an arm produced by this inventive method will have a lowered mounting seat for the spring. Compared with the prior art steel arm shown in Fig. 1, it will have similar strength properties, mainly due to the two reinforcing channels. The weight will typically be reduced with more than 50%.

Claims

Claims
1. A method of manufacturing a control arm for a wheel suspension assembly in a car, said arm being intended to support a spring unit, c h a r a c t e r i z e d i n the following steps: cutting a straight length of an aluminium profile, said profile having two parallel closed channels (1, 2) connected by a bridge (3) , stretching and bending said profile into an arch, pressing the profile together in end portions, forming a seat for the spring unit in the bridge (3) by pressing, forming mounting holes in the end portions of the profile.
2. A method as claimed in claim 1, c h a r a c t e r i z e d i n punching a hole in the middle of said mounting seat for said spring unit.
3. An aluminium control arm for a wheel suspension assembly in a car, said arm being intended to support a spring unit, said arm including a first and a second end, c h a r a c t e r i z e d i n a seat (42) for the spring unit in a bridge (41), said seat (42) being located between said first and second ends of the arm, a first side channel (43) going from the first to the second end of the arm passing the seat (42) on a first side, a second side channel (44) passing from the first to the second end of the arm passing the seat (42) on a second side, the first and second side channels (43, 44) being connected by said bridge (41) , the arm being pressed together at its first and second ends defining narrowed mounting points, and said narrowed mounting points including mounting holes (45,
PCT/NO2005/000408 2004-10-27 2005-10-27 An aluminium control arm and a method for the production of the same WO2006046876A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
DE112005002470.9T DE112005002470B4 (en) 2004-10-27 2005-10-27 Aluminum handlebar and method of making the same

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NO20044636 2004-10-27
NO20044636A NO20044636L (en) 2004-10-27 2004-10-27 Control arm and method of manufacture thereof

Publications (1)

Publication Number Publication Date
WO2006046876A1 true WO2006046876A1 (en) 2006-05-04

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ID=35057736

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/NO2005/000408 WO2006046876A1 (en) 2004-10-27 2005-10-27 An aluminium control arm and a method for the production of the same

Country Status (3)

Country Link
DE (1) DE112005002470B4 (en)
NO (1) NO20044636L (en)
WO (1) WO2006046876A1 (en)

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008082305A1 (en) * 2006-12-28 2008-07-10 Raufoss Technology As Control arm
CN102756029A (en) * 2012-07-27 2012-10-31 中国第一汽车股份有限公司 Hot-press forming method of rear axle half shell of automobile
US8616570B2 (en) 2010-11-19 2013-12-31 Benteler Automobiltechnik Gmbh Method for producing a control arm, and a control arm
EP2679415A1 (en) * 2012-06-29 2014-01-01 Audi Ag Suspension arm
EP2774786A1 (en) * 2013-03-08 2014-09-10 Audi Ag Method for producing a suspension arm and suspension arm for a vehicle
US20150115561A1 (en) * 2012-02-21 2015-04-30 Yorozu Corporation Vehicle suspension arm
US20160009154A1 (en) * 2014-07-09 2016-01-14 Ford Global Technologies, Llc Suspension member
EP3031637A1 (en) * 2014-12-12 2016-06-15 Benteler Automobiltechnik GmbH Multi-part spring link
DE102016116023A1 (en) 2015-08-28 2017-03-02 Raufoss Technology As control arm
WO2017118771A1 (en) * 2016-01-04 2017-07-13 Fundiciones De Vera, S.A. Method for producing profiles for leaf springs
US9974702B2 (en) 2013-06-24 2018-05-22 Autolift S.R.L. Wheelchair lift
CN109968932A (en) * 2017-12-27 2019-07-05 长城汽车股份有限公司 After control arm configuration

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2641576B1 (en) 2012-03-21 2015-04-22 AMF-Bruns GmbH & Co. KG Vehicle lift

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Publication number Priority date Publication date Assignee Title
US5362090A (en) * 1992-09-22 1994-11-08 Suzuki Motor Corporation Suspension of motor vehicle
WO2001032979A1 (en) * 1999-11-03 2001-05-10 Raufoss Technology As Control arm and method for manufacturing
EP1297977A2 (en) * 2001-09-28 2003-04-02 FIAT AUTO S.p.A. Axle having a torsionally deformable cross member for the rear suspension of a motor vehicle, and method for production of such axle
FR2833529A1 (en) * 2001-12-14 2003-06-20 Auto Chassis Int Flexible axle for automobile non-driving wheels comprises single transverse torsion element connecting to fixing points having developing section central part and end angled portions
WO2005002890A1 (en) * 2003-07-03 2005-01-13 Aisin Keikinzoku Co., Ltd. Suspension arm

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Publication number Priority date Publication date Assignee Title
US3797852A (en) * 1972-08-07 1974-03-19 Chrysler Corp Suspension system
JP3505899B2 (en) * 1996-03-04 2004-03-15 トヨタ自動車株式会社 Vehicle suspension arm
JP3122397B2 (en) * 1997-01-23 2001-01-09 フタバ産業株式会社 Suspension arm

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5362090A (en) * 1992-09-22 1994-11-08 Suzuki Motor Corporation Suspension of motor vehicle
WO2001032979A1 (en) * 1999-11-03 2001-05-10 Raufoss Technology As Control arm and method for manufacturing
EP1297977A2 (en) * 2001-09-28 2003-04-02 FIAT AUTO S.p.A. Axle having a torsionally deformable cross member for the rear suspension of a motor vehicle, and method for production of such axle
FR2833529A1 (en) * 2001-12-14 2003-06-20 Auto Chassis Int Flexible axle for automobile non-driving wheels comprises single transverse torsion element connecting to fixing points having developing section central part and end angled portions
WO2005002890A1 (en) * 2003-07-03 2005-01-13 Aisin Keikinzoku Co., Ltd. Suspension arm

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008082305A1 (en) * 2006-12-28 2008-07-10 Raufoss Technology As Control arm
US8616570B2 (en) 2010-11-19 2013-12-31 Benteler Automobiltechnik Gmbh Method for producing a control arm, and a control arm
US20150115561A1 (en) * 2012-02-21 2015-04-30 Yorozu Corporation Vehicle suspension arm
EP2679415A1 (en) * 2012-06-29 2014-01-01 Audi Ag Suspension arm
CN102756029A (en) * 2012-07-27 2012-10-31 中国第一汽车股份有限公司 Hot-press forming method of rear axle half shell of automobile
EP2774786A1 (en) * 2013-03-08 2014-09-10 Audi Ag Method for producing a suspension arm and suspension arm for a vehicle
US9974702B2 (en) 2013-06-24 2018-05-22 Autolift S.R.L. Wheelchair lift
US20160009154A1 (en) * 2014-07-09 2016-01-14 Ford Global Technologies, Llc Suspension member
US20160167472A1 (en) * 2014-12-12 2016-06-16 Benteler Automobiltechnik Gmbh Multipiece spring link
US9895947B2 (en) 2014-12-12 2018-02-20 Benteler Automobiltechnik Gmbh Multipiece spring link
EP3031637A1 (en) * 2014-12-12 2016-06-15 Benteler Automobiltechnik GmbH Multi-part spring link
DE102016116023A1 (en) 2015-08-28 2017-03-02 Raufoss Technology As control arm
US9944141B2 (en) 2015-08-28 2018-04-17 Raufoss Technology As Control arm
WO2017118771A1 (en) * 2016-01-04 2017-07-13 Fundiciones De Vera, S.A. Method for producing profiles for leaf springs
CN109968932A (en) * 2017-12-27 2019-07-05 长城汽车股份有限公司 After control arm configuration

Also Published As

Publication number Publication date
NO20044636D0 (en) 2004-10-27
NO20044636L (en) 2006-04-28
DE112005002470B4 (en) 2014-09-18
DE112005002470T5 (en) 2007-09-20

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