Axle-to-Beam Connection Using Window Weld and Alignment Assembly
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Solution Overview
Problem
Existing axle-to-beam connections in heavy-duty vehicle suspension systems face issues with stress risers due to line welds, increased manufacturing complexity and cost, and the need for on-site welding for assembly, while also requiring additional bump stops for protection during jounce events.
Innovation Solution
The proposed axle-to-beam connection utilizes a top pad with a window weld for secure attachment, eliminating line welds and incorporating a mechanical bump stop, allowing for removable attachment without welding equipment and separate shipment of components, thus reducing stress and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If line welds are used to attach the axle to the beam, then the connection strength is improved, but stress risers are created that reduce reliability
Solution Approach 1:
The patent removes line welds from the axle-to-beam connection entirely, extracting the harmful stress-rising element while maintaining connection strength through alternative means (alignment assembly with mounting surfaces and fasteners).
Solution Approach 2:
The patent introduces an alignment assembly as an intermediary component between the axle and beam, which provides mounting surfaces for attachment without creating stress risers on the axle itself, thereby mediating the connection in a stress-free manner.
2Ease of manufacture
If traditional axle-to-beam connections are used, then manufacturing is simplified, but additional bump stops are required increasing device complexity
Solution Approach 1:
The patent merges the bump stop function into the alignment assembly structure itself, where the alignment assembly provides both alignment and mechanical bump stop protection in a single integrated component, eliminating the need for separate bump stops.
Solution Approach 2:
The alignment assembly serves multiple functions simultaneously: it provides precise alignment between axle and beam, serves as the mounting structure for attachment, and acts as a mechanical bump stop for protection during jounce events, embodying multi-functionality.
3Strength
If welding is required for assembly, then connection strength is improved, but on-site assembly becomes difficult requiring specialized equipment
Solution Approach 1:
The patent replaces the welding process (thermal/chemical joining) with a mechanical fastening system using the alignment assembly and fasteners, allowing strong connections to be made on-site with basic tools without requiring welding equipment.
4Quantity of substance
If the axle and suspension assembly are shipped separately, then shipping efficiency is improved, but alignment precision becomes difficult to achieve
Solution Approach 1:
The alignment assembly is pre-installed on the suspension assembly during manufacturing with precise alignment features, so that when shipped separately and assembled on-site, the pre-prepared alignment surfaces ensure accurate alignment without requiring complex alignment procedures.
Data Source
Figure 1
Figure 2
Figure 2A
AI summary
An axle-to-beam connection for a suspension assembly of an axle/suspension system of a heavy-duty vehicle including an axle (217), a beam (212), and a top pad (270). The beam (212) includes an alignment assembly (250) for aligning the axle with the beam. The top pad (270) includes an integrally-formed bump stop boss (280) and is fixedly attached to the axle and removably attached to the alignment assembly of the beam.