Integrated Axle Bracket with Molded Connection Points
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Solution Overview
Problem
The production of existing axle carriers for vehicles is complex and expensive due to the number of individual parts and the design of connection points, which also results in high weight and reduced rigidity.
Innovation Solution
A composite axle carrier design featuring a single profiled cross member with light metal brackets and molded connection points for wishbones, tie rods, and spring/damping units, with reinforced ribs for increased rigidity, and sleeve-like attachment points for body connection using rubber bearings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional multi-part axle carriers with separate profile carriers and connection points are used, then manufacturing flexibility is maintained, but production costs increase and weight increases
Solution Approach 1:
The patent combines multiple separate components (profile carrier, connection points, brackets) into a single integrated axle carrier made of light metal. The console is formed as one piece with molded-in connection points and integrated brackets, eliminating the need for separate profile carriers and reducing the total number of parts while maintaining structural functionality.
Solution Approach 2:
The axle carrier is manufactured from light metal (aluminum alloy) using die-casting processes, replacing traditional steel or composite profile carriers. This material substitution reduces weight while the die-casting process enables complex integrated geometries that would be difficult to achieve with traditional manufacturing methods.
2Ease of manufacture
If traditional welded profile carriers are used, then structural strength is achieved, but production complexity and cost increase
Solution Approach 1:
The patent replaces mechanical assembly processes (welding, bolting separate components) with a single die-casting manufacturing process. The entire axle carrier including connection points and brackets is formed in one piece through mold casting, eliminating multiple welding operations and assembly steps while maintaining structural integrity through the casting process itself.
3Stability of the object's composition
If conventional connection points are used, then basic attachment functionality is provided, but rigidity is reduced
Solution Approach 1:
The connection points are molded directly into the console as integral features rather than being separate attached components. The brackets and connection points form a unified structure with the main console body, creating stiffer load paths and improving overall rigidity while simplifying the design by eliminating separate connection point components.
Data Source
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AI summary
The invention relates to an axle bracket for the rear axle of a motor vehicle, as an assembled structural unit comprising a single profiled transversal carrier (1) and consoles (2, 3) fixed to the end regions of the structural unit. Said consoles are each provided with moulded binding positions (A, B; C, D; E; F; G, H) for at least three of the following units - the upper transverse links (6), the lower transverse links (4), the track rods (5), and the spring or damping unit (7) - and each comprise at least two moulded binding positions (G, H) for attaching the axle bracket to the bodywork.