Hollow Axle Beam Stiffener Radial Expansion Lock
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Solution Overview
Problem
Existing hollow beam structures for axles face challenges in efficiently incorporating local stiffeners to enhance strength at mounting interfaces for suspension components without increasing weight or complexity, particularly due to the closed nature of the beams.
Innovation Solution
A hollow beam with apertures for receiving and radially expanding a tubular stiffener to create a mechanical lock, either through a press-fit or weld attachment, which securely fixes the stiffener within the beam, thereby increasing the structural strength without adding significant weight or cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a two-piece hollow beam structure with C-shaped beam and bottom plate is used, then the hollow beam structure can be formed, but the assembly process becomes time-consuming and complex requiring tube positioning and welding before bottom plate installation
Solution Approach 1:
The stiffener is divided into multiple segments that can be inserted through apertures in the bottom plate and assembled independently within the hollow cavity, allowing the bottom plate to be installed first without requiring complex pre-assembly of stiffeners
Solution Approach 2:
The stiffener segments are pre-configured with expansion mechanisms that enable them to be inserted through the bottom plate apertures in advance, and then expanded later to secure themselves without requiring complex welding operations before bottom plate installation
2Strength
If local stiffeners are added to strengthen mounting interfaces, then the strength at suspension component attachment locations is improved, but the weight of the hollow beam structure increases
Solution Approach 1:
Stiffeners are installed only at specific locations within the hollow beam where suspension components are mounted, providing localized strength enhancement rather than uniformly strengthening the entire beam structure
Solution Approach 2:
The stiffener utilizes a composite construction with an outer peripheral surface and inner peripheral surface, creating a multi-layered structure that provides high strength-to-weight ratio at the mounting interface
3Ease of manufacture
If the hollow beam structure is kept closed without apertures, then the structural integrity is maintained, but stiffeners cannot be efficiently installed within the hollow cavity
Solution Approach 1:
The hollow beam bottom plate is segmented with multiple apertures that allow stiffener insertion while maintaining overall structural integrity through strategic placement and sizing of the apertures
Solution Approach 2:
Apertures are pre-formed in the bottom plate during manufacturing, enabling straightforward stiffener insertion without requiring complex post-assembly modifications or compromising the structural design
4Reliability
If tube stiffeners are welded to inner wall surfaces, then the stiffeners are securely attached, but the assembly process becomes time-consuming and costly
Solution Approach 1:
The stiffener is designed with self-expanding capabilities through radial expansion subsequent to insertion, forming a shoulder portion that provides a mechanical lock to prevent removal, eliminating the need for external welding operations
Solution Approach 2:
The welding process is replaced with a mechanical expansion and locking mechanism, where radial expansion of the tubular stiffener creates a press-fit connection that secures the stiffener without requiring thermal or chemical bonding processes
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
This method provides a cost-effective and efficient way to enhance the strength of hollow axle beams by securely attaching stiffeners, simplifying the assembly process and maintaining the weight benefits of hollow beam structures.
Implementation Method 1
This expansion forms a shoulder portion on the tubular stiffener that provides a mechanical lock to prevent the tubular stiffener from being removed from the axle beam
Implementation Method 2
The attachment interface comprises a weld attachment interface
Implementation Method 3
The attachment interface comprises a pres-fit attachment interface
Data Source
AI summary
An axle beam includes a hollow beam body with at least first and second apertures formed in opposing wall portions of the hollow beam body. A stiffener is received within the first and second apertures and is fixed to the hollow beam body at an attachment interface.