Axle Arm to Axle Tube Joining Structure for Lighter Truck Axles
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Solution Overview
Problem
Existing axle control arms for commercial vehicles are complex to produce, offer limited weight reduction opportunities, and lack standardization, resulting in insufficient component reuse and reduced service life.
Innovation Solution
A composite axle control arm and axle tube system featuring a connecting element with distinct sections for welded connections, allowing for simplified production and enhanced weight reduction, featuring a connecting element with a first section for the link element and a second section that encompasses the axle tube, enabling optimal strength and weight distribution through a combination of welded and non-positive connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multi-part axle control arms are manufactured with separate connecting elements and control elements, then manufacturing complexity increases, but weight reduction and service life improvement are limited
Solution Approach 1:
The axle control arm is divided into separate connecting element and control element that can be manufactured independently and then assembled through welding. This segmentation allows each component to be optimized separately for weight and manufacturing efficiency while maintaining overall structural integrity
Solution Approach 2:
The patent employs composite construction by joining different metal components (connecting element and control element) through welded connections. This composite approach enables weight reduction by using optimized material distributions while achieving required strength through the combination of parts
2Ease of manufacture
If traditional axle control arm designs are used, then manufacturing processes remain complex, but standardization of components is insufficient
Solution Approach 1:
The connecting element is designed as a universal component with standardized geometry and connection interfaces that can be used across different axle control arm configurations. This universality enables the same connecting element to work with various control element designs, achieving component standardization and reducing manufacturing complexity through reuse
Solution Approach 2:
The connecting element is pre-designed and pre-manufactured as a standardized component before final assembly. This preliminary preparation of standardized parts simplifies the overall manufacturing process by reducing on-site fabrication complexity and enabling modular assembly
3Reliability
If the connecting element encompasses the axle tube completely, then welded connection to axle tube is improved, but assembly complexity increases
Solution Approach 1:
The connecting element provides partial encompassment of the axle tube rather than complete enclosure. This partial action is sufficient to achieve the required welded connection strength and structural stability while avoiding the excessive complexity that would result from complete encapsulation
Solution Approach 2:
The connection between connecting element and axle tube is achieved through segmented welded joints at specific locations rather than continuous encirclement. This segmentation maintains connection reliability through strategically placed welds while reducing assembly complexity by eliminating the need for complete tube encompassment
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 solution simplifies production, enhances weight reduction, increases service life, and allows for universal component use by optimizing the distribution of supporting structures, achieving high strength and low weight while minimizing assembly complexity and improving handling of the axle tube and control arm.
Implementation Method 1
the connecting element has a first connecting section in which a welded connection to the control element can be made or has been made
Implementation Method 2
the connecting element has a second connecting section in which a welded connection to an axle tube can be made or has been made
Data Source
Figure 1~2
Figure 3
AI summary
Disclosed is an axle tie rod to be attached to an axle tube of a commercial vehicle, comprising a joining element and at least one tie rod element; the joining element has a first joining section in which a welded joint to the tie rod element can be created; the joining element has a second joining section in which a welded joint to an axle tube can be created; the second joining section is designed to embrace the axle tube.