Asymmetrical Axle Tower Design for Load Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Designing attachment devices for asymmetrical vehicle axles that can efficiently transfer and disperse loads from multifunctional axle alignment and load reacting devices like torque boxes to the axle housing without overloading or fracturing, while maintaining stability and preventing skewing.
Innovation Solution
The use of asymmetrical axle towers with differently shaped compression and tension sides, featuring scalloped or contoured surfaces and radiused corners to distribute stress, and an asymmetrical footprint to accommodate the asymmetric positioning of the differential housing, along with a unique weldment structure for attachment to the axle housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If symmetrical axle towers are used to attach the torque box to the axle housing, then the attachment structure is simple and manufacturing is easier, but the asymmetric positioning requirements of the differential housing cannot be accommodated, leading to improper load distribution
Solution Approach 1:
The patent applies asymmetry by designing the axle tower with different configurations for its left and right sides. The first side includes a first appendage with specific geometry while the second side includes a second appendage with different geometry, allowing each side to accommodate the asymmetric positioning requirements of the differential housing while maintaining proper load distribution across the axle housing.
Solution Approach 2:
The patent applies local quality by giving different structural properties to different parts of the axle tower. The compression side and tension side have different geometries and material distributions optimized for their specific functional requirements, with the compression side designed to handle compressive loads and the tension side designed to handle tensile loads from the torque box attachment.
2Device complexity
If the axle tower structure is simplified, then manufacturing cost and complexity are reduced, but the ability to disperse and absorb loads without overloading or fracturing the axle housing is compromised
Solution Approach 1:
The patent applies curvature by incorporating radiused corners at the base of the axle tower where it attaches to the axle housing. These rounded transitions eliminate stress concentration points that would occur with sharp corners, allowing the tower to better absorb and disperse loads while maintaining structural integrity and preventing fracture of the axle housing.
Solution Approach 2:
The patent applies segmentation by dividing the axle tower into distinct functional components: side plates, appendages with different geometries for left and right sides, and radiused corner sections. This segmentation allows each component to be optimized for its specific function while maintaining overall structural efficiency and reliability.
3Reliability
If the axle towers are mounted at asymmetric points on the differential housing to center the torque box, then proper load transfer is achieved, but the axle towers must be of different heights and configurations increasing design complexity
Solution Approach 1:
The patent applies asymmetry by designing the axle tower with different configurations for its left and right sides. The first side includes a first appendage with specific geometry while the second side includes a second appendage with different geometry, allowing each side to accommodate the asymmetric positioning requirements of the differential housing while maintaining proper load distribution.
4Ease of manufacture
If sharp corners are used in the axle tower structure, then manufacturing is simpler, but stress concentration occurs leading to potential failure of the axle or differential housing
Solution Approach 1:
The patent applies curvature by incorporating radiused corners at the base of the axle tower where it attaches to the axle housing. These rounded transitions eliminate stress concentration points that would occur with sharp corners, allowing the tower to better absorb and disperse loads while maintaining structural integrity and preventing fracture of the axle housing.
Data Source
AI summary
The invention is directed to vehicle suspension systems and components thereof including attachment devices for mounting an axle alignment and/or load reacting mechanism to an axle. Disclosed herein are axle towers used for connecting a torque box to an axle. The axle tower of the present invention can include one or more features to absorb and disperse loads to the axle. The axle tower has a more contoured or curved edge on the side plate that experiences a compressive force than a similar edge on the side plate that experiences a tensile force. Furthermore, the axle tower has appendages that extend out from the side plates providing a large footprint on the axle housing. At least one of the appendages extending from the side plate experiencing a compressive force has a curved or radiused corner. Also, the axle towers include an inner plate having an off-centered slot where the troque box connects. The off-centered slot provides additional material to absorb the compressive force experienced on one side of the inner plate.