Axle Coupling Assembly Reducing Unsprung Weight
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Solution Overview
Problem
Existing suspension systems in vehicles face challenges in reducing unsprung weight, which affects ride comfort and performance due to significant unsprung weight in trucks and heavy vehicles, and existing methods fail to effectively accommodate caster or pinion angles, leading to issues like wheel hop and vibration.
Innovation Solution
The use of U-shaped fastener assemblies with flanges and a mounting pad to couple the axle to energy storing suspension components like leaf springs, allowing for reduced size and weight while automatically accommodating caster or pinion angles, thereby reducing nut face angularity and improving alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional heavy axle coupling assemblies are used, then structural strength and stability are maintained, but unsprung weight increases leading to reduced ride comfort and increased vibration
Solution Approach 1:
The axle coupling assembly utilizes composite construction combining aluminum alloy components (mounting pad, flanges) with steel fasteners, creating a lightweight yet strong structure that reduces unsprung weight while maintaining structural integrity under suspension loads
Solution Approach 2:
The coupling assembly is divided into separate functional components including U-shaped fastener assemblies, flanges with grooved surfaces, and a mounting pad, allowing each part to be optimized for its specific function while collectively achieving weight reduction and strength requirements
2Adaptability or versatility
If rigid fixed-angle coupling is used, then alignment precision is maintained, but adaptability to caster or pinion angle variations is lost causing wheel hop and vibration
Solution Approach 1:
The grooved surfaces on flanges enable dynamic angular adjustment of the U-shaped fastener assemblies to accommodate caster or pinion angles, while the connectors maintain precise parallel engagement with the mounting pad, combining adaptability with alignment precision
Solution Approach 2:
The grooved surfaces act as intermediary elements between the fixed mounting pad and the adjustable fasteners, allowing angular accommodation while maintaining precise alignment through the intermediate grooved engagement interface
3Ease of manufacture
If conventional fastening methods are used, then ease of manufacture is maintained, but nut face angularity problems occur when accommodating caster or pinion angle
Solution Approach 1:
The U-shaped fastener assemblies with grooved surface engagement allow the connectors to self-align and maintain parallel engagement with the mounting pad while accommodating angular variations, eliminating nut face angularity issues without complex manufacturing procedures
Data Source
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AI summary
An axle coupling assembly and method for coupling a vehicle axle to an energy storing suspension component are disclosed. The assembly includes first and second U-shaped fastener assemblies, first and second flanges configured for connection to the vehicle axle, a mounting pad and a suspension component such as a leaf spring or a leading or trailing arm disposed between the first and second flanges and mounting pad.