Aerodynamic Trailer Strut Assembly for Impact-Resistant Side Skirts
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Solution Overview
Problem
Conventional long-haul cargo trailers experience significant aerodynamic drag and turbulent airflow, leading to increased fuel consumption and NOx emissions, along with premature wear and noise due to transient wind-force loading.
Innovation Solution
A strut assembly is used to mount an aerodynamic fairing assembly to the trailer, comprising a mounting bracket, strut body, and composite spring, which resist inward deflection upon impact to maintain airflow and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional trailers are used without aerodynamic modifications, then the structure is simple and cost-effective, but significant turbulent airflow and aerodynamic drag occur between the axles below the trailer box, increasing fuel consumption and NOx emissions
Solution Approach 1:
The aerodynamic fairing is divided into multiple panels (side panels, end panels, bottom panels) that can be independently manufactured and assembled. Each panel is attached to the trailer frame through separate mounting brackets, allowing modular construction and easier manufacturing while collectively reducing turbulent airflow between axles
Solution Approach 2:
The fairing extends the trailer structure into the previously empty space between the axles and below the trailer box. By adding this three-dimensional aerodynamic envelope, the system smooths airflow in the previously turbulent region, reducing drag without compromising the simple base structure
2Strength
If rigid mounting structures are used to attach the aerodynamic fairing, then structural integrity is maintained, but transient wind-force loading causes vibration and premature wear of external vehicle surfaces
Solution Approach 1:
The mounting system incorporates dynamic elements including spring-loaded mounting brackets and flexible connections that allow the fairing panels to move slightly with wind forces. This dynamic mounting approach maintains structural integrity while reducing stress concentrations that cause premature wear and noise
Solution Approach 2:
The mounting brackets include cushioning elements and flexible connectors that absorb transient wind-force loading before it reaches the fairing panels and trailer structure. This beforehand cushioning prevents vibration and reduces wear on external surfaces
3Strength
If the fairing structure is made more robust to resist impact forces, then structural strength is improved, but the weight of the aerodynamic apparatus increases
Solution Approach 1:
The mounting brackets use spring-loaded mechanisms that change their mechanical parameters (stiffness, force distribution) based on impact conditions. During normal operation, the springs provide flexible mounting, but during impact, the spring force increases to distribute and resist impact loads, maintaining strength without requiring heavier materials
Solution Approach 2:
The fairing panels utilize composite material construction combining rigid panels for structural integrity with flexible mounting connections. This composite approach provides adequate impact resistance while keeping the overall weight lower than a fully rigid structure would require
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The strut assembly minimizes internal deflection of the side skirt during side impacts, reducing drag and wear, and enhances aerodynamic performance by maintaining smooth airflow and reducing the risk of damage.
Implementation Method 1
The substantially rectangular composite spring may be coupled to an upper surface of the strut body and configured to contact an underside of the mounting plate of the mounting bracket to resist inward deflection from an external force applied to the strut body.
Implementation Method 2
The strut assembly minimizes internal deflection of the side skirt during side impacts, reducing drag and wear
Data Source
AI summary
A strut assembly for mounting an aerodynamic fairing assembly for attachment to a trailer of a tractor-trailer having a centerline, transverse structural support members extending between sides of the trailer, and longitudinal members extending along a length of the trailer. The strut assembly may comprise a mounting plate, a strut body, and a spring. The spring may be substantially rectangular. The mounting bracket comprising a mounting plate and a pair of spaced apart sidewalls. The strut body rotatably may be coupled to the pair of spaced apart sidewalls on the mounting bracket. The spring may be coupled to an upper surface of the strut body and configured to contact an underside of the mounting plate of the mounting bracket to resist inward deflection from an external force applied to the strut body.