IE20040230A1 - A modular independent suspension system - Google Patents

Abstract

A modular independent suspension system (1) includes a mounting frame (2) which has a deep U-shape and forms a structural cross member for mounting between a pair of longitudinal chassis rails (3) of a heavy vehicle. The mounting frame (2) has a pair of side members (5) interconnected at their lower ends by a cross member formed by a pair of spaced-apart cross beams (7). An independent wheel suspension assembly (8) is mounted on each side member (5) of the mounting frame (2). <Figure 1>

Description

A modular independent suspension system” This invention relates to a modular independent suspension system, in particular for 5 heavy vehicles.

During vehicle construction the assembly of the various components of a suspension system on a vehicle chassis by a vehicle manufacturer is often cumbersome and time consuming, requiring the drilling or other preparation of mounting stations for attachment of various suspension elements to the chassis at different locations.

The present invention is directed towards overcoming this problem and simplifying this task.

According to the invention there is provided a modular independent suspension system for mounting on a heavy vehicle chassis which includes a pair of spacedapart longitudinal chassis rails, the system including a U-shaped mounting frame having a pair of side members interconnected at their lower ends by a cross member, an upper end of each side member having means for engagement with one of said 0 longitudinal chassis rails, an independent wheel suspension assembly being mounted on each side member of the mounting frame.

Advantageously the suspension system of the invention allows pre-assembly and setup of the complete suspension system as an off-line assembly. When delivered in this modular form to a vehicle manufacturer, the modular independent suspension system of the invention greatly simplifies the task of fitting the suspension system to the vehicle chassis. Essentially, the suspension system of the invention can be simply bolted to the chassis rails. in a particularly preferred embodiment the mounting frame forms a structural cross member for the vehicle chassis.

Preferably the mounting frame has a deep U-shape which provides clearance for other vehicle systems, such as engine and gearbox for example, which protrude.

OPEN TO PUBL’C INSPECTION UNDER SECTION 28 ANL RULE 23 - 2 £ 04 023 0 below the chassis rail level on the vehicle.

In another embodiment each wheel suspension assembly includes an upper control arm and an associated lower control arm, an inner end of each control arm being pivotally mounted on the side member, outer ends of the control arms supporting a wheel carrier therebetween, and spring and damping means being mounted between one of said control arms and the side member.

Preferably the spring and damper means is mounted between the lower control arm and the side member.

In another embodiment the suspension medium comprises a coil spring. Preferably a bump stop is also provided to limit upward movement of the control arms and wheel carried .thereon. Conveniently the bump stop may be mounted on the side member for engagement with the upper control arm.

In a further embodiment each side member has a stepped seat at its upper end for reception of a chassis rail.

In another embodiment a lower end of each side member is formed by an inwardly facing C-shaped channel element and the cross member is formed by a pair of spaced-apart box section cross beams which extend between and engage within the channel elements of the side members.

In a further embodiment each side member includes an inwardly open C-shaped channel member at a lower end of the side member, a side panel mounted on the channel member and extending upwardly and outwardly of the channel member with a stepped seat at an upper end of the side panel for reception of a chassis rail, and two or more side panel support members mounted on an outer face of the side panel and extending upwardly from the channel member and substantially perpendicularly outwardly from the side panel.

In another embodiment the side panel is formed from a single metal plate bent intermediate it’s ends. *040230 In another embodiment an outwardly extending reinforcing head piece is mounted on an outer face of the side panel at an uppermost end of the side panel above the side panel support members.

In another aspect the invention provides a vehicle incorporating the suspension system.

In a still further aspect the invention provides a mounting frame for the suspension system as described herein.

The invention will be more clearly understood by the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings, in which; Fig. 1 is a perspective view of a modular independent suspension system of the invention, shown mounted on a pair of longitudinal chassis rails; 'Fig 2 is a detail perspective view of a mounting frame forming portion of the suspension system; and Fig. 3 is a detail perspective view showing a side member of the suspension system with an independent wheel suspension assembly mounted thereon.

Referring to the drawings, there is illustrated a modular independent suspension system according to the invention indicated generally by the reference numeral 1. The system 1 includes a metal mounting frame 2 (illustrated in Fig. 2) which has a deep U-shape and forms a structural cross member for mounting between a pair of longitudinal chassis rails 3 of a heavy vehicle. The mounting frame 2 has a pair of side members 5 interconnected at their lower ends by a cross member 6 formed in this case by a pair of spaced-apart cross beams 7. An independent wheel suspension assembly 8 is mounted on each side member 5 of the mounting frame 2.

Each side member 5 of the mounting frame 2 has at its lower end an inwardly facing C0402JQ C-shaped channel element 10. Outer ends 11,12 of each box section cross beam 7 locate within the channel elements 10 as shown in Fig. 2. They can be bolted or welded together. Reinforcing webs 13 are mounted within each channel element 10.

Extending upwardly and outwardly from each channel element 10 are side supports 14, 15, 16. These side supports 14,15, 16 support a side panel formed by an inner plate 17 at their inner edges. A lower end 40 of the plate 17 is inclined upwardly and outwardly of the channel element 10. An upper end of the plate 17 is bent to form a stepped seat 18 for reception of a chassis rail 3. A reinforcing head piece 19 is provided at an upper end of the side supports 14, 15, 16 outside the plate 17 at an upper end of the plate 17. A number of through holes 20 are provided in a vertical flange 21a and horizontal flange 21b of the seat 18 to facilitate bolting to the chassis rails 3.

A C-shaped reinforcing bracket 29 fits within the channel of each rail 3 in alignment with the step 18 as shown in Fig. 1, the mounting bolts passing through the step 18, rail 3 and bracket 29.

Each wheel suspension assembly 8 includes an upper control arm 22 and an associated lower control arm 23. An inner end of the upper control arm 22 is pivotally mounted on the side member 5 by a bearing support (not shown) which allows pivoting movement of the upper control arm 22 in a vertical direction. Similarly, the lower control arm 23 which is Y-shaped has a forked inner end 24 pivotally mounted in bearing blocks 25 bolted to an outer face of the lower channel element 10 of the side member 5. Ball joints 26 are provided at an outer end of each control arm 22, 23 for supporting a wheel carrier, in this case a wheel hub 27, therebetween. Each wheel hub 27 carries a wheel (not shown).

A coil spring 30 and associated damper 31 extends between the lower control arm 23 and the head portion 19 of the side member 5. The spring 30 and damper 31 assembly is secured to the lower control arm 23 by a pivoting mounting bracket 32 and associated pivot pin 33 which extends through the lower control arm 23. A bump stop 35 mounted at an upper end of the side member 5 is engagable with the upper control arm 22 to limit upward movement of the upper control arm 22. - 5 IE 04 023 0 A steering system, indicated generally by the reference numeral 40 for steering the wheels carried on the hubs 27, may also be provided as shown in Fig. 1.

In use, the modular suspension system 1 of the invention advantageously can be preassembled and set up prior to delivery in modular form to a vehicle manufacturer who then bolts the system between the chassis rails 3 of his vehicle chassis. It will be appreciated that the suspension system 1 can be fitted as a self-contained unit to the vehicle chassis with as few as one connecting bolt pattern for each chassis rail 3. Further, the mounting frame 2 of the suspension system 1 forms a structural crossmember which reinforces the chassis of the vehicle. The deep U-shape of the mounting frame 2 enables other vehicle systems, such as an engine and gearbox for example, which protrude beneath the chassis rail level to be accommodated.

It will be appreciated that the suspension system of the invention is very compact and is easy to mount on the chassis rails.

The invention is not limited to the embodiments hereinbefore described which may be varied in both construction and detail within the scope of the appended claims.

Claims (14)

1. Ά modular independent suspension system for mounting on a heavy vehicle chassis which includes a pair of spaced-apart longitudinal chassis rails, the system including a U-shaped mounting frame having a pair of side members interconnected at their lower ends by a cross member, an upper end of each side member having means for engagement with one of said longitudinal chassis rails, an independent wheel suspension assembly being mounted on each side member of the mounting frame.

2. A suspension system as claimed in claim 1 wherein the mounting frame forms a structural cross member for the vehicle chassis, and the mounting frame has a deep U-shape which provides clearance for other vehicle systems, such as engine and gearbox for example, which protrude below the chassis rail level on the vehicle.

3. A suspension system as claimed in claim 1 or 2 wherein each wheel suspension assembly includes an upper control arm and an associated lower control arm, an inner end of each control arm being pivotally mounted on the side member, outer ends of the control arms supporting a wheel carrier therebetween, and spring and damping means being mounted between one of said control arms and the side member.

4. A suspension system as claimed in claim 3 wherein the spring and damping means is mounted between the lower control arm and the side member.

5. A suspension system as claimed in claim 3 or claim 4 wherein the suspension medium comprises a coil spring.

6. A suspension system as claimed in any of claims 3 to 5 wherein a bump stop is provided to limit upward movement of the control arms and wheel carried -thereon.

7. A suspension system as claimed in claim 6 wherein the bump stop is - 7 Ε 04023 0 mounted on the side member for engagement with the upper control arm.

8. A suspension system as claimed in any preceding claim wherein each side member has a stepped seat at its upper end for reception of a chassis rail, and a lower end of each side member is formed by an inwardly facing Cshaped channel element and the cross member is formed by a pair of spaced-apart box section cross beams which extend between and engage within the channel elements of the side members.

9. A suspension system as claimed in any preceding claim wherein each side member includes an inwardly open C-shaped channel member at a lower end of the side member, a side panel mounted on the channel member and extending upwardly and outwardly of the channel member with a stepped seat at an upper end of the side panel for reception of a chassis rail, and two or more side panel support members mounted on an outer face of the side panel and extending upwardly from the channel member and substantially perpendicularly outwardly from the side panel.

10. A suspension system as claimed in claim 9 wherein the side panel is formed from a single metal plate bent intermediate it’s ends.

11. -A suspension system as claimed in claim 9 or claim 10 wherein an outwardly extending reinforcing head piece is mounted on an outer face of the side panel at an uppermost end of the side panel above the side panel support members.

12. A modular independent suspension system for a vehicle substantially as hereinbefore described with reference to the accompanying drawings.

13. A vehicle incorporating a modular independent suspension system as claimed in any preceding claim.

14. A mounting frame for a modular independent suspension system as claimed in any of claims 1 to 12 substantially as hereinbefore described with reference - 8 to the accompanying drawings.