集成传导和优化结构的快速成型车轮悬挂系统

Fabian Weitz, C. Debnar, Michael Frey, Frank Gauterin
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摘要

社会的环保意识不断增强,城市化进程日益加快,这就需要有新颖的汽车概念。增材制造(AM)技术的使用扩大了部件开发的设计自由度。在本文中,将利用这些技术进一步开发新型模块化汽车概念的前轴悬架。车轮悬挂部件的优化基于一种新方法,该方法已在之前的工作中得到应用。该方法基于用于部件强度设计的行业标准载荷情况,以及为悬挂部件设计和悬挂部件适当配置而确定的可用安装空间。利用数值方法确定的适合力流的部件几何形状,在控制臂中整合信息、能量和材料传输线时进行了优化,并尽可能广泛地将传输线用作承重结构。采用高强度轻金属,以最大限度地降低部件质量。部件上有开口,用于铺设电缆。流体输送则通过集成在叉骨中的管路来实现。悬挂部件的最终几何形状通过整个悬挂模型的有限元分析(FEA)进行验证。采用这种方法的结果是悬挂部件更轻,功能集成度更高。功能集成度的提高减少了所需的安装空间,从而改善了车辆的整体性,并获得了更大的前轮间隙,增加了可能的转向角度,从而提高了机动性。簧下质量的减少可以改善驾驶性能,并对车辆能耗产生积极影响。此外,传导部分的集成简化了前桥悬架的装配。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
Additively Manufactured Wheel Suspension System with Integrated Conductions and Optimized Structure
Society's growing environmental awareness and increasing urbanisation require new and innovative vehicle concepts. The use of additive manufacturing (AM) expands the design freedom in component development. In this paper, these are utilised to further develop a front axle suspension for a new type of modular vehicle concept. The wheel suspension components are optimised on the basis of a new method that has already been applied in previous work. This is based on industry-standard load cases for the strength design of the components, as well as the available installation space determined for the design of the suspension components and the suitable configuration of the suspension components. The component geometries identified using numerical methods that are suitable for the force flow are optimised with regard to the integration of information, energy and material-carrying lines in the control arms and the lines are used as load-bearing structures as extensively as possible. High-strength light metals are used to minimise the component masses. Openings are provided in the components for routing electrical cables. The fluid transport is realised using lines integrated into the wishbones. The final geometries of the suspension components are then validated by a finite element analysis (FEA) of the entire suspension model. The result of the method used are lighter suspension components with a maximum degree of functional integration. The increased functional integration reduces the required installation space, which improves the vehicle package and achieves greater front wheel clearance, which increases the possible steering angles and thus improves maneuverability. The reduction in unsprung masses can improve driving behaviour and has a positive effect on the vehicle's energy consumption. In addition, the integration of the conductions section simplifies the assembly of the front axle suspension.
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