DE102022133813A1 - Axle support structure and axle support thereof as well as manufacturing and assembly methods therefor - Google Patents

Abstract

An axle support structure (100) is proposed with two axle supports (20L, 20R), which are attached to a cross-strut structure, the two axle supports (20L, 20R) each having a flange (25) for a wheel bearing for mounting a wheel, and the two flanges (25) are arranged opposite one another, so that two wheels, which form a double wheel, can be mounted on pivot bearings between the axle supports (20L, 20R). The cross strut construction consists of a cross strut (10) that acts as a torsion bar and one of the axle supports (20L, 20R) is attached to each end. The two axle supports (20L, 20R) each consist of a set of several flat sheet metal parts, which are folded in sections and/or welded together to form a three-dimensional structure. This significantly lighter, because it is not massive, construction is particularly suitable for converting a vehicle into a three-wheeled vehicle that can be approved for driving license class A1.

Description

The invention relates to an axle support structure for a vehicle, in particular an axle support structure which has a cross member and two axle supports, each of which is attached to one of the two ends of the cross member.

Furthermore, the invention relates to the construction of axle carriers suitable for this axle carrier structure.

The invention also relates to a method for producing such an axle support structure and an assembly method for installing the same in a vehicle (for the purpose of converting it into a vehicle with a double-wheel rear axle.

From the EP 2 899 103 B1 an axle support structure is known which is suitable for converting an originally four-wheeled vehicle in order to equip this vehicle with a modified rear axle construction, which has two wheels mounted at a short distance, which thus form a double wheel. This converts the vehicle into a three-wheeled vehicle that can be approved for driving license class A1, which means that young driving license holders aged 16 and over can also drive this vehicle. The axle carrier structure disclosed there has, among other things, two solid axle carriers which are attached to a frame-like cross strut construction, the two axle carriers each having a flange for a wheel bearing for mounting a wheel, and the two flanges are arranged opposite one another, so that between The two wheels or the double wheel can be mounted on pivot bearings on the axle supports.

However, due to the solidly designed axle carrier and the frame-shaped cross member, the axle carrier structure there is quite heavy and bulky. Therefore, in order to install this axle support structure, the wheel arches must be expanded towards the center of the vehicle and stiffening beams must also be provided to stabilize the vehicle body (see claim 1 there).

In DE 35 26 272 A1 An axle support is disclosed, which is designed as a welded sheet metal box.

In DE 10 2007 030 929 A1 An axle support is disclosed which consists of two cross members and two longitudinal members, with one of the cross members (the rear one) being realized by two sheet metal shells welded together.

And DE 10 2014 204 052 A1 discloses a stiffening structure of a two-track vehicle in the form of a shear field designed as a sheet metal piece, which is attached to a subframe functioning as an axle support and optionally to longitudinal members of the vehicle and is further supported on side sills of the vehicle body, this support being provided via support arms formed in the sheet metal piece is.

The object of the present invention is to overcome the above disadvantages and in particular to propose an axle support structure that is relatively light and compact, thereby eliminating the need to expand the wheel arches towards the center of the vehicle and to provide stiffening supports to stabilize the vehicle body .

The task is solved by an axle support structure with the features of claim 1.

Accordingly, the axle support structure has a cross strut construction, which consists of a cross strut acting as a torsion bar, at each end of which one of the axle supports is attached; and the two axle supports each consist of a set of several flat sheet metal parts, which are folded in sections and/or welded together to form a three-dimensional structure.

This results in a significantly lighter, because not massive, construction of axle supports and, also because of the cross strut acting as a torsion bar, results in a very compact design, whereby the requirements for stability are fully met despite the lightweight construction.

The invention also includes the axle support as such, which is characterized in that it consists of a set of several flat sheet metal parts which are folded in sections and/or welded together to form a three-dimensional structure or construction.

Furthermore, the invention also includes the use of such an axle support structure in a motor vehicle, in particular for the purpose of converting a four-wheeled vehicle into a three-wheeled vehicle.

The invention also includes a method (1000) for producing an axle support, in particular by cutting out sheet metal parts, folding them and welding them.

Finally, the invention also includes a method for producing an axle support structure using two axle supports manufactured in this way.

Advantageous embodiments of the invention result from the subclaims.

Accordingly, each set preferably comprises at least two flat sheet metal parts, each of which has at least three sections that are bent to one another at angles between 35° to 90°, each of these sheet metal parts having at least two recesses. Such a set of sheet metal parts is suitable for the light and stable construction of an axle carrier and an axle carrier structure constructed with it. Compared to solid axle supports, the use of sheet metal, such as sheet steel or black sheet, saves significant weight; In addition, the cutouts provided also reduce the weight. Folding in sections in an angle range of 35° to 90° enables a compact and very stable construction and ultimately a three-dimensional axle support structure that is significantly lighter and more compact than the known structures.

Preferably, two of the flat sheet metal parts each have an opening into which one end of the cross strut can be inserted. This makes it much easier to assemble and accurately align the structure, especially before welding it together. Preferably, the crossbar is designed as a T-shaped torsion bar and the respective opening is designed as a T-shaped slot; This allows the parts to be connected to one another in a form-fitting manner before they are welded together.

In further advantageous embodiments, each set comprises at least two flat sheet metal parts that are not folded, with at least one of these sheet metal parts having a recess and/or a cutout. This means that as many components as possible are provided with material recesses and/or cutouts.

The present invention also relates to a method for producing such an axle carrier, in particular the construction of the axle carrier as part of an axle carrier structure, the method comprising the following steps: cutting a set of several flat sheet metal parts from a sheet metal, the set comprising at least two sheet metal parts, each having at least three sections and an opening, and wherein the set comprises at least two flat sheet metal parts that are not folded; Bending the sections to each other at angles between 35° and 90°; and welding the folded and non-folded sheet metal parts into a three-dimensional structure.

In addition, the invention also relates to the assembly of the axle carrier structure using a method with the following steps or sequence of steps: producing two axle carriers according to the sequence of steps according to the method for producing the axle carriers; and attaching the axle beams to one of the ends of a cross member.

• 1a zeigt in einer dreidimensionalen Darstellung den Aufbau einer Achsträger-Struktur nach einem ersten Ausführungsbeispiel;
• 1b zeigt in einer Draufsicht den Aufbau der Achsträger-Struktur nach dem ersten Ausführungsbeispiel;
• 1c zeigt in einer dreidimensionalen Darstellung den Aufbau eines der beiden Achsträger der Achsträger-Struktur nach dem ersten Ausführungsbeispiel;
• 2a zeigt in einer dreidimensionalen Darstellung den Aufbau einer Achsträger-Struktur nach einem zweiten Ausführungsbeispiel;
• 2b zeigt in einer Draufsicht den Aufbau der Achsträger-Struktur nach dem zweiten Ausführungsbeispiel;
• 2c zeigt in einer Draufsicht als Abwicklungsschema den Satz flacher Blechteile zum Aufbau der Achsträger-Struktur nach dem zweiten Ausführungsbeispiel;
• 3a zeigt in einer dreidimensionalen Darstellung von oben den Aufbau einer Achsträger-Struktur nach einem dritten Ausführungsbeispiel;
• 3b zeigt in einer dreidimensionalen Darstellung von unten den Aufbau der Achsträger-Struktur nach einem dritten Ausführungsbeispiel;
• 3c zeigt in einer Draufsicht den Aufbau der Achsträger-Struktur nach dem dritten Ausführungsbeispiel;
• 3d zeigt in einer Seitenansicht den Aufbau eines der Achsträger der Achsträger-Struktur nach dem dritten Ausführungsbeispiel;
• 4a ist ein Ablaufdiagramm zur Veranschaulichung eines Verfahrens zur Herstellung eines (einzelnen) Achsträgers; und
• 4b ist ein Ablaufdiagramm zur Veranschaulichung eines Verfahrens zur Herstellung einer Achsträger-Struktur umfassend zwei Achsträger und einen Querträger.

The invention is described in detail below using exemplary embodiments, with reference being made to the accompanying drawings, which show the following schematic representations:

• 1a shows a three-dimensional representation of the structure of an axle support structure according to a first exemplary embodiment;
• 1b shows a top view of the structure of the axle support structure according to the first exemplary embodiment;
• 1c shows a three-dimensional representation of the structure of one of the two axle supports of the axle support structure according to the first exemplary embodiment;
• 2a shows a three-dimensional representation of the structure of an axle support structure according to a second exemplary embodiment;
• 2 B shows a top view of the structure of the axle support structure according to the second exemplary embodiment;
• 2c shows a top view as a development diagram of the set of flat sheet metal parts for building the axle support structure according to the second exemplary embodiment;
• 3a shows a three-dimensional representation from above of the structure of an axle support structure according to a third exemplary embodiment;
• 3b shows a three-dimensional view from below of the structure of the axle support structure according to a third exemplary embodiment;
• 3c shows a top view of the structure of the axle support structure according to the third exemplary embodiment;
• 3d shows a side view of the structure of one of the axle supports of the axle support structure according to the third exemplary embodiment;
• 4a is a flowchart illustrating a method for producing a (single) axle support; and
• 4b is a flowchart for illustrating a method for producing an axle support structure comprising two axle supports and a cross member.

First we look at the 1a and 1b Reference: An axle support structure 100 is shown in a first embodiment relating to its use as a rear axle support structure. The axle carrier structure 100 has a cross member or a cross strut 10, to which two axle carriers are attached, namely the left axle carrier 20L and the right axle carrier 20R. One of the axle beams is located at one end of the cross member, with the respective connection between the axle member and the cross member being approximately a third of the length of the axle member (see also 1c ). Each axle carrier 20L and 20R has a receptacle 21 in one end for an axle rubber, via which the respective axle carrier is pivotally connected to the body of the vehicle (not shown). The axle supports 20L and 20R are pivotally mounted relative to the body (rotary axis bearing with pivot axis X - see 1b) . Since the cross strut has a certain flexibility and acts in particular as a torsion bar, the axle supports 20L and 20R can also be pivoted slightly against each other; This particularly improves the dynamic driving characteristics of a vehicle equipped with the axle support structure.

To cushion the construction, each axle support has a support surface 22 for a spiral spring (not shown), i.e. a so-called spring plate. To dampen the pivoting construction, each axle support also has an attachment for a shock absorber (not shown). This means that the axle supports 20L and 20R can be pivoted in a spring-damped manner using the rotation axis bearing on the respective receptacle 21. As previously stated, the cross strut 10, which acts as a torsion bar, also pivots the two axle supports against each other/in opposite directions, with the cross strut providing the restoring force.

The axle supports 20L and 20R are each equipped with a flange 26 for a wheel bearing, these being aligned towards the center of the structure, i.e. the two flanges 25 are arranged opposite one another, so that between the axle supports 20L and 20R there are two wheels, which are a Form a double wheel that can be mounted on pivot bearings (the wheels are not shown). A double wheel is understood to mean, in particular, a set of two wheels arranged parallel to one another, in which the distance between the centers of the contact surfaces of the wheels or tires on the road is less than 460 mm.

• Der Abstand D1 zwischen den beiden Flanschen 25 beträgt hier z.B. 400 mm, er sollte möglichst im Bereich von 300-500 mm liegen.
• Die Länge L1, d.h. der Abstand von Aufnahme 21 (Lochmitte) bis zum Flansch 25 (Lochmitte), beträgt hier z.B. 556 mm, er sollte möglichst im Bereich von 450-600 mm liegen.
• Die Länge L2, d.h. der Abstand von Befestigungsstelle (Öffnung/Schlitz S) zur Querstrebe 10 bis zum Flansch 25 (Lochmitte), beträgt hier z.B. 333 mm, er sollte möglichst im Bereich von 250-400 mm liegen. Somit befindet sich die Befestigungsstelle (Öffnung/Schlitz S) bei etwa einem Drittel der Länge L1.
• Die Querstrebe 10 ist hier als T-Träger mit den Maßen 60x60x7 mm ausgebildet und fungiert somit auch als Drehstab, der eine federelastische Verschränkung der Achsträger erlaubt und somit der Gesamtkonstruktion eine Flexibilität gibt, die das, insbesondere dynamische, Fahrverhalten des Fahrzeuges deutlich verbessert.
• Der Abstand D2 beträgt hier z.B. 90 mm (er kann zwischen 60-110 mm betragen) und bezieht sich auf den Versatz zwischen der Position der Aufnahme 21 für das Achsgummi und der Position des Flansches 25 (Lochmitte) für die Aufnahme des Radlagers. Somit wird in Relation zur Schwenkachse X das am Flansch 25 montierte Radlager etwas angehoben, d.h. das montierte Rad liegt höher in der Karosserie des Fahrzeugs, was wiederum die Fahrstabilität erhöht.

The axle support structure is designed to be very compact and has the following dimensions (see in particular 1b and 1c ):

• The distance D1 between the two flanges 25 is here, for example, 400 mm; if possible, it should be in the range of 300-500 mm.
• The length L1, ie the distance from the mount 21 (center of the hole) to the flange 25 (center of the hole), is 556 mm, for example; it should be in the range of 450-600 mm if possible.
• The length L2, ie the distance from the fastening point (opening/slot S) to the cross strut 10 to the flange 25 (center of the hole), is here, for example, 333 mm; it should be in the range of 250-400 mm if possible. The attachment point (opening/slot S) is therefore located at about a third of the length L1.
• The cross strut 10 is designed here as a T-beam with dimensions of 60x60x7 mm and therefore also functions as a torsion bar, which allows the axle beams to be interlocked in a resilient manner and thus the overall con The structure provides flexibility, which significantly improves the vehicle's driving behavior, particularly dynamic handling.
• The distance D2 here is, for example, 90 mm (it can be between 60-110 mm) and refers to the offset between the position of the mount 21 for the axle rubber and the position of the flange 25 (center of the hole) for the mount of the wheel bearing. The wheel bearing mounted on the flange 25 is thus raised slightly in relation to the pivot axis

• Die zweite Ausführungsform der Achsträger-Struktur 100* ist ähnlich dem ersten Ausführungsbeispiel aufgebaut. Auch die zweite Ausführungsform hat einen als Drehstab wirkenden Querträger 10, an dem zwei Achsträger angeordnet sind, nämlich ein linker Achsträger 200L und ein rechter Achsträger 200R; ebenso sind Aufnahmen 21 für Achsgummis sowie Flansche 25 für Radlager vorgesehen. Was die Konstruktion der Achsträger angeht, so unterscheidet sich diese durch eine abgewandelte Weise der Befestigung 26* für die Stoßdämpfer. Ansonsten sind die beiden Ausführungsformen im Wesentlichen gleich.

The structure of the axle carrier structure and in particular the construction of the respective axle carrier will now be explained in more detail using a second exemplary embodiment and with reference to 2a-c described:

• The second embodiment of the axle support structure 100* is constructed similarly to the first embodiment. The second embodiment also has a cross member 10 acting as a torsion bar, on which two axle carriers are arranged, namely a left axle carrier 200L and a right axle carrier 200R; There are also receptacles 21 for axle rubbers and flanges 25 for wheel bearings. As far as the construction of the axle supports is concerned, this differs in a modified way of fastening 26* for the shock absorbers. Otherwise, the two embodiments are essentially the same.

• Wie dort zu sehen ist, besteht der Achsträger 200R aus einem Satz mehrerer flacher Blechteile, hier z.B. auch Stahlblech der Stärke 5 mm. Es werden hier sieben Blechteile 210, 220, 230, 240, 250, 260 und 270 verwendet, die aus dem Stahlblech mittels Wasserstrahl oder Laser herausgeschnitten wurden.

As already at the 1a , 1c and 2a As can be seen, the respective axle support consists of several flat sheet metal parts that are put together to form a three-dimensional structure. The structure of the respective axle carrier is explained in detail below using the 2a and 2c described using the example of the right axle carrier 200R:

• As you can see there, the axle carrier 200R consists of a set of several flat sheet metal parts, here for example sheet steel with a thickness of 5 mm. Seven sheet metal parts 210, 220, 230, 240, 250, 260 and 270 are used here, which were cut out of the steel sheet using a water jet or laser.

In the 2c The contours of the sheet metal parts are shown in the form of a development diagram. Many of the larger sheet metal parts, such as 210, 220 and 230, have (hole-like) recesses A in order to save material weight without reducing stability. Even smaller sheet metal parts, such as 240, are designed to save material and weight by having cutouts A' (non-hole-like recesses) on them.

In the example shown, a first sheet metal part 210 is provided with three sections 211, 212 and 213, which are folded against each other in order to create a multi-dimensional structure. The same applies to a second sheet metal part 220, which even has four sections 221, 222, 223 and 224. The ones in the 2c The arrow symbols shown are intended to show how the respective section is folded. The arrowhead refers to the section to be folded; and the orientation of the arrow (clockwise or counterclockwise) indicates whether this section will be folded upward (counterclockwise arrow) or downward (clockwise arrow) out of the plane. For example, section 224 is bent upwards relative to section 223, and the latter in turn is also bent upwards towards section 222. On the other hand, section 262 is bent downwards towards section 261. The angles (bending angles) to be maintained when folding are in the range from 35° to 90°. In the present example, the following angles must be maintained, with a bending radius of R 2.5 being preferred: Adjacent sections angle (bending angle) 224 to 223 90° upwards 223 to 222 36.9° upwards 221 to 222 90° upwards 213 to 212 46.7° up 212 to 211 37.7° upwards 262 to 261 90° downwards

With these angles specified here, the affected components 210, 220 and 260 can be formed into multi-dimensional partial structures, which in turn represent components for the axle carrier 200R. Together with the flat, non-folded sheet metal parts 230, 240, 250 and 270, each is then welded the three-dimensional axle carrier 200R was built. Like a synopsis of the 2a until 2c illustrated, a light but very stable axle carrier 200R is ultimately created.

Based on 3a-d a third exemplary embodiment is described. The axle carrier structure 100# shown there also essentially consists of two axle carriers 20L and 20R, each of which has been assembled from individual sheet steel or black sheet parts (see description of 2c ) and a cross member or a cross strut 10, which is designed as a T-shaped torsion bar. Since all exemplary embodiments (see also 1a-c and 2a-c ) are fundamentally similar, the same reference numbers can be used accordingly. The differences between the exemplary embodiments lie in particular in the details (dimensions and dimensions) of the various designs, which are each optimized for a specific vehicle type. The construction according to 3a-d is, for example, optimized for the small car type “VW Up”.

The 3a-d show the third exemplary embodiment in different views. The cut AA in 3c shows the side plan view of the right axle support, i.e. the view in 3d .

From the 3c-d dimensions of the construction there are marked; these are the following values: X1 = 1163 mm; X2 = 1066mm; X3 =1020mm; Y1 = 117.5mm; Y2 = 177.5mm; Y3 = 363.5mm; Y4 = 492mm and Z1 = 76.51mm.

• Schritt 1001: Ausschneiden eines Satzes 200 mehrerer flacher Blechteile 210 - 270 aus einem Blech, wobei der Satz 200 zumindest zwei Blechteile 210, 220 umfasst, die abgekantet werden und jeweils mindestens drei Abschnitte 211-213; 221-224 und eine Öffnung S aufweisen, und wobei der Satz 200 mindestens zwei flache Blechteile 230, 240 umfasst, die nicht abgekantet werden;
• Schritt 1002: Abkanten der Abschnitte 211-213; 221-224 zueinander in Winkeln zwischen 35° bis 90°; und
• Schritt 1003: Verschweißen der abgekanteten und nicht abgekanteten Blechteile 210-270 zu einem dreidimensionalen Gebilde für den gewünschten Achsträger (z.B. rechtsseitige oder linksseitige Ausführung).

The respective axle carrier is manufactured using a process 1000, which is shown as a schematic flow diagram in 4a is shown and includes the following steps:

• Step 1001: Cutting a set 200 of several flat sheet metal parts 210 - 270 from a sheet, the set 200 comprising at least two sheet metal parts 210, 220 that are folded and at least three sections 211 - 213 each; 221-224 and an opening S, and wherein the set 200 comprises at least two flat sheet metal parts 230, 240 which are not folded;
• Step 1002: Folding sections 211-213; 221-224 to each other at angles between 35° to 90°; and
• Step 1003: Welding the folded and non-folded sheet metal parts 210-270 into a three-dimensional structure for the desired axle support (eg right-hand or left-hand version).

• Schritte 2001 und 2002: Herstellen von jeweils einer der beiden Achsträger 200L, 200R gemäß dem obigen Verfahren 1000; dann
• Schritt 2003: Befestigen der Achsträger 200L, 200R jeweils an einem der Enden eines Querträgers 10*.

The assembly of an axle support structure according to the invention can be carried out according to the method 2000, which is shown as a schematic flow diagram in 4b is shown and includes the following steps:

• Steps 2001 and 2002: Manufacture one of the two axle supports 200L, 200R according to the above method 1000; then
• Step 2003: Attach the axle supports 200L, 200R each to one of the ends of a cross member 10*.

Overall, the structure of an axle support structure and its production are disclosed, which enable the realization of a three-wheeled vehicle, the axle support structure being light, compact and yet stable, so that when it is installed in the vehicle, the wheel arches towards the center of the vehicle can be dispensed with to be expanded and to provide stiffening supports to stabilize the vehicle body.

• ◯ Zuerst wird die Original Achse ausgebaut;
• ◯ Dann wird eine Schablone in den Kofferraum gelegt; an dieser Schablone entlang wird die Reserveradmulde ausgeschnitten;
• ◯ Dabei bleiben die Träger vom und hinten und die beiden seitlichen Träger links und rechts unverändert vorhanden;
• ◯ Dann werden die Bremsen und Radlager von der alten Achse abgenommen und auf die neue Achse gebaut;
• ◯ Weil die Räder jetzt innen liegend montiert sind, werden die Bremsen seitenverkehrt eingebaut (die rechte nach links und die linke nach rechts);
• ◯ Die original ABS- und ESP-Sensoren finden weiterhin Verwendung;
• ◯ Allerdings sollten geänderte Bremsleitungen eingebaut werden (sie müssen etwas länger sein und eine andere Biegung haben);
• ◯ Es werden geänderte Handbremsseile werden eingesetzt, auch diese müssen etwas länger sein;
• ◯ Nun werden zwei Federn (hier werden nicht die originalen eingesetzt) mit einer anderen Federrate - sie sind deutlich härter - eingesetzt. Oben sind sie in der ursprünglichen Halterung geführt, unten in der neuen Achse;
• ◯ Die original Stoßdämpfer werden weiter verwendet;
• ◯ Dann wird die Hinterachse an den originalen Aufhängungspunkten unter Verwendung der originalen Achslager eingebaut;
• ◯ Eine neue Abdeckung aus Blech wird im Kofferraum montiert, sie ist z.B. genietet und mit Karosseriekleber verklebt;
• ◯ Die Reifen, die hinten eingesetzt werden, sind in der Dimension gleich denen, die serienmäßig verbaut werden und die Originalfelgen werden verwendet;
• ◯ Der Auspuff wird gekürzt und die Abgase werden mit einem Winkelstück vor der Achse abgeleitet;
• ◯ Die Leistung wird durch eine Umprogrammierung des Steuergerätes auf 15 KW begrenzt - zwecks Zulassung für die Führerscheinklasse A1;
• ◯ Das Gewicht des Fahrzeugs liegt unter 1000 kg.

As far as installing the axle support structure according to the invention in a commercially available motor vehicle is concerned, the procedure can be as follows:

• ◯ First the original axle is removed;
• ◯ Then a template is placed in the trunk; The spare wheel well is cut out along this template;
• ◯ The straps at the front and back and the two side straps on the left and right remain unchanged;
• ◯ Then the brakes and wheel bearings are removed from the old axle and installed on the new axle;
• ◯ Because the wheels are now mounted on the inside, the brakes are installed reversed (the right to the left and the left to the right);
• ◯ The original ABS and ESP sensors are still used;
• ◯ However, modified brake lines should be installed (they must be slightly longer and have a different bend);
• ◯ Modified handbrake cables will be used, these must also be slightly longer;
• ◯ Now two springs (not the original ones are used here) with a different spring rate - they are significantly harder - are used. At the top they are guided in the original holder, at the bottom in the new axle;
• ◯ The original shock absorbers continue to be used;
• ◯ Then the rear axle is installed at the original suspension points using the original axle bearings;
• ◯ A new sheet metal cover is installed in the trunk; for example, it is riveted and glued with body adhesive;
• ◯ The tires used at the rear are the same size as those installed as standard and the original rims are used;
• ◯ The exhaust is shortened and the exhaust gases are diverted with an elbow in front of the axle;
• ◯ The power is limited to 15 KW by reprogramming the control unit - for the purpose of approval for driving license class A1;
• ◯ The weight of the vehicle is less than 1000 kg.

Reference symbol list

100

Axle support structure (first embodiment)

10

Cross brace (torsion bar)

20L, 20R

first or second axle carrier

21

Mounting for axle rubber (pivot point bearing)

22

Support surface (spring plate) for spiral spring

25

Flange for wheel bearings

26

Fastening shock absorbers

100*

Axle support structure (second embodiment)

10*

Cross brace (torsion bar)

200L, 200R

first or second axle carrier

210

first part with three sections 211, 212 and 213

220

second part with four sections 221, 222, 223 and 224

230

third part

240

fourth part

250

fifth part (flange)

260

sixth part with attachment shock absorber

270

Seventh part (also shock absorber attachment)

100#

Axle support structure (third embodiment)

1000

Method for making an axle beam with steps 1001-1003

2000

Method for producing an axle support structure with steps 2001-2003

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 2899103 B1 [0004]
• DE 3526272 A1 [0006]
• DE 102007030929 A1 [0007]
• DE 102014204052 A1 [0008]

Claims (11)

Axle support structure (100; 100*, 100#) for a vehicle, comprising: two axle supports (20L, 20R) attached to a cross-member structure, the two axle supports (20L, 20R) each having a flange (25) for a Have wheel bearings for mounting a wheel, and the two flanges (25) are arranged opposite one another, so that two wheels, which form a double wheel, can be mounted in a pivoting manner between the axle supports (20L, 20R), characterized in that the cross strut construction consists of one There is a cross strut (10) acting as a torsion bar, at each end of which one of the axle supports (20L, 20R) is attached, and that the two axle supports (20L, 20R) each consist of a set (200) of several flat sheet metal parts (210 - 270 ) which are folded in sections and/or welded together to form a three-dimensional structure. Axle support structure (100; 100*, 100#). Claim 1 , characterized in that each set (200) comprises at least two flat sheet metal parts (210, 220), each of which has at least three sections (211-213; 221-224) which are bent to one another at angles between 35 ° and 90 °, each of these sheet metal parts having at least two recesses (A). Axle support structure (100; 100*, 100#). Claim 2 , characterized in that two of the flat sheet metal parts (210, 220) each have an opening (S) into which one end of the cross strut (10*) is inserted. Axle support structure (100; 100*, 100#). Claim 3 , characterized in that the cross strut (10, 10*) is designed as a T-shaped torsion bar and that the respective opening (S) is designed as a T-shaped slot. Axle support structure (100; 100*, 100#) according to one of the preceding claims, characterized in that each set (200) comprises at least two flat sheet metal parts (230, 240) which are not folded, at least one (230) of which Sheet metal parts have a recess (A) and/or a cutout (A#). Axle support structure (100; 100*, 100#) according to one of the preceding claims, characterized in that the distance (D1) between the two flanges (25) is in a range of 300-500 mm; and/or that the length (L1), which relates to the distance from the receptacle (21) to the flange (25), is in a range of 450-600 mm, and/or that the length (L2), which concerns the Distance from the opening (S) of the cross member (10) to the flange (25) is in a range of 250-400 mm; and/or that the cross brace (10) is designed as a T-beam with dimensions of 60x60x7 mm; and/or that the distance (D2), which relates to an offset between the position of the receptacle (21) for the axle rubber and the position of the flange (25), is in a range of 60-110 mm. Axle support (20R; 200R) for an axle support structure (100; 100* 100#) according to one of the preceding claims, characterized in that the axle support (20R; 200R) consists of a set (200) of several flat sheet metal parts (210 - 270 ), which are folded in sections and/or welded together to form a three-dimensional structure. Axle carrier (20R; 200R). Claim 7 , characterized in that the axle support (20R; 200R) is produced from a sheet metal by cutting a set (200) of several flat sheet metal parts (210 - 270), the set (200) comprising at least two sheet metal parts (210, 220), which are to be folded and each have at least three sections (211-213; 221-224) and an opening (S), and wherein the set (200) comprises at least two flat sheet metal parts (230, 240) which are not to be folded; that the sections (211-213; 221-224) are bent to one another at angles between 35° to 90°; and that the folded and non-folded sheet metal parts (210-270) are welded to form a three-dimensional structure. Use of an axle support structure (100; 100*; 100#) of the preceding claims in a motor vehicle. Method (1000) for producing an axle carrier (20R; 200R) according to one of Claims 7 - 8th , characterized by the following steps: (1001): cutting a set (200) of several flat sheet metal parts (210 - 270) from a sheet, the set (200) comprising at least two sheet metal parts (210, 220), which are folded and each at least have three sections (211-213; 221-224) and an opening (S), and wherein the set (200) comprises at least two flat sheet metal parts (230, 240) which are not folded; (1002): Folding the sections (211-213; 221-224) to each other at angles between 35° and 90°; and (1003): Welding the folded and non-folded sheet metal parts (210-270) into a three-dimensional structure designed as an axle support (200R). Method (2000) for producing an axle support structure (100; 100*, 100#) according to one of Claims 1 - 6 , characterized by the following steps: (2001): Manufacture of a first axle carrier (20R; 200R) according to the method Claim 10 as the right-hand axle support (20R; 200R) of the axle support structure (100; 100*, 100#); (2001): Manufacture a second axle carrier (20L; 200L) according to the method Claim 10 as the left-side axle support (20L; 200L) of the axle support structure (100; 100*, 100#); and (2003): Attach the two axle supports (20R, 200R; 20L, 200L) to one of the ends of a cross member (10*).

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