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BR-102024018290-A2 - MANUFACTURING PROCESS FOR AUTOMOTIVE REAR SUSPENSION COMPONENT AND APPLICATION OF THE RESPECTIVE COMPONENT IN VALIDATION OF BRAKE LINE ARRANGEMENT

BR102024018290A2BR 102024018290 A2BR102024018290 A2BR 102024018290A2BR-102024018290-A2

Abstract

This invention introduces an innovative methodology for obtaining rapid and accurate validation of the physical arrangement of brake lines in an automotive vehicle, based on the conformation of the rear suspension component, called the frame rail, through 3D printing. This eliminates the need to develop and manufacture new tooling if validation is not achieved. The validation analysis is performed by incorporating the 3D-printed frame rail into a real test vehicle and measuring the distances from the brake lines to the other components, according to the suspension design specifications. If validation is not achieved, the necessary adjustments are made to the printing design and a new frame rail is obtained until validation occurs.

Inventors

  • CASSIANO SILVA FERRI
  • ALESSANDRO BARIONI
  • HERSEN HAYS SANTOS MACEDO

Assignees

  • STELLANTIS AUTOMOVEIS BRASIL LTDA

Dates

Publication Date
20260317
Application Date
20240905

Claims (4)

  1. 1. Manufacturing process of an automotive rear suspension component and application of the respective component in the validation of the physical arrangement of brake lines, characterized by comprising the following steps: production of a rear torsion beam (1) by means of 3D printing; assembly of the obtained beam (1) on a real test vehicle (2); with the vehicle (2) suspended, moving the vehicle suspension (2) according to predetermined parameters; and measuring the distances of the brake lines (3) to the other components, for validation of their physical arrangement.
  2. 2. Manufacturing process for an automotive rear suspension component and application of the component obtained in the physical arrangement validation of brake conduits, according to claim 1, characterized in that the rear torsion beam (1) comprises an assembly formed by a side arm (1a) and a wheel housing (1b).
  3. 3. Manufacturing process for an automotive rear suspension component and application of the component obtained in the physical arrangement validation of brake conduits, according to claim 1, characterized in that the rear torsion beam (1) obtained by 3D printing has mechanical resistance to breakage or cracking to withstand the applied stresses so that it can be mounted on a real vehicle (2) and the other stages of the process can be carried out.
  4. 4. Manufacturing process for an automotive rear suspension component and application of the component obtained in the physical arrangement validation of brake conduits, according to claim (1), characterized in that the rear torsion beam (1) obtained by 3D printing is capable of undergoing changes in its configuration and being applied for testing without the need for forming new tooling.

Description

FIELD OF THE INVENTION [0001] The present invention relates to the technical field of the automotive industry, focusing more specifically on the development of an innovative manufacturing methodology for a rear torsion beam, a component of a rear suspension, as well as the use of said beam for the streamlined verification of the physical arrangement of the brake lines of a vehicle. BACKGROUND OF THE INVENTION [0002] The set of elements that connects the wheels to the main structure, or chassis, of a motor vehicle is defined as the suspension. Born from the need to reconcile comfort and handling, the suspension acts as an elastic medium between the terrain and the vehicle, adding even greater stability to it. It works to prevent irregularities in the road from being transmitted directly to the vehicle. It basically comprises: springs, an elastic connection that smoothly absorbs and transmits road imperfections, providing comfortable movement; shock absorbers, responsible for damping the roll, thus reducing the oscillation produced by the spring assembly; and a series of structural connecting elements that, arranged according to a special anchoring geometry, control the vertical movements of the wheels. It is precisely this group of elements, such as axles, articulated axles, bars, arms, and others, that, associated with the type of connection to the wheels, such as coupled wheels or independent wheels, defines the type of suspension used in the vehicle. Other vehicle components can be associated with these elements, and it is common to find brake lines fixed or passing extremely close to axles, half-shafts, and especially connecting elements between the wheel and other suspension parts, such as torsion beams. This condition is particularly relevant in the rear suspension region of the vehicle, due to the proximity of these lines to other components, such as the fuel tank, body support, the shock absorbers themselves, and others, where contact between the brake lines is absolutely prohibited. Thus, since there is constant movement of the suspension components, including mainly the rear torsion beam, as well as the brake lines themselves, the analysis of the dimensioning and shape of this torsion beam and the spatial distribution of the brake lines is critical. However, there is no way to produce the torsion beam other than in its final version. Thus, after its design, production, and assembly, the rear torsion beam is tested to verify the physical arrangement of the brake lines, in order to observe if there is sufficient space for its operation according to the standards. It is important to emphasize that, even with all the required parameters, the validation of the spatial arrangement of the brake lines can only be effectively obtained in a real test. When this physical arrangement is invalidated, the beam needs to be modified and all the tooling for its production is altered, causing a significant impact on cost and time. [0003] Searching the state of the art patent literature, the following documents were found: [0004] Document EP2310217 discloses a suspension crossmember using a transverse axle and torsion beam for a motor vehicle, particularly for a rear suspension, as well as the method for its production. [0005] Document EP2327573 discloses a torsion beam rear suspension with rear or front drive configurations, where rear arms made of sheet metal with applied supports are provided, designed to allow the application of the steering wheel assembly (hub, etc.) at one end and the transmission passage at the opposite end. [0006] Thus, considering the state-of-the-art solutions, it is evident that none of them has been able to solve the technical problem associated with the fact that, when it is necessary to change the configuration of the rear torsion beam due to the invalidation of the spatial arrangement of the brake lines, all its tooling is altered. It should be noted that none of the prior art approaches or provides sufficient guidance to conceive an adequate solution to such a problem. [0007] In view of the points presented, the importance and urgency of a technical solution capable of overcoming the current gap in this technical field is clear. Taking these points into account, the present invention aims to offer a favorable solution to the problems previously presented. OBJECTIVES OF THE INVENTION [0008] The present invention, in a first objective, aims to provide a process for manufacturing or obtaining an automotive rear suspension component, particularly represented by a rear torsion beam, without necessarily being in its final version. [0009] Another objective of the invention is to provide a process for manufacturing or obtaining an automotive rear suspension component, particularly represented by a rear torsion beam, capable of undergoing changes in its configuration without the need for forming new tooling. [0010] Another objective of the present invention is to provide a manufacturing or obt