Commercial Vehicle Axle Force Transmission Segmentation
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Solution Overview
Problem
Existing axle designs for commercial vehicles face challenges in stability due to concentrated stress points, high manufacturing costs, and corrosion risks, particularly in the connection between the axle tube and wishbone, which can lead to cracking and breakage under torsional and axial forces.
Innovation Solution
The axle design incorporates a force transmission means with a form-fitting connection for torque transmission and a clamping connection for normal force transmission, arranged at a distance from each other along the axle tube, using an adapter plate that separates torque and normal force transmission, reducing stress concentration and allowing for easier assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a welded connection is used between the axle tube and wishbone, then the connection strength is improved, but the manufacturing cost increases and corrosion risk increases
Solution Approach 1:
The connection between axle tube and wishbone is segmented into two separate connection points: a form-fitting connection for torque transmission and a clamping connection for axial force transmission. This segmentation allows each connection to be optimized for its specific function without requiring expensive welding processes, while maintaining overall connection strength.
Solution Approach 2:
A force transmission means acts as an intermediary element between the axle tube and wishbone, providing both form-fitting and clamping connections. This intermediary component enables force transmission without direct welding between the axle tube and wishbone, reducing manufacturing complexity and corrosion risk while maintaining connection strength.
2Force
If a form-fitting connection with toothed structure is used, then the torque transmission is improved, but the manufacturing complexity increases
Solution Approach 1:
The force transmission means is segmented into distinct functional zones: a form-fitting connection zone with toothed structure for torque transmission and a clamping connection zone for axial force transmission. This segmentation allows the complex toothed structure to be localized to where it is most needed, while other areas use simpler connection methods.
Solution Approach 2:
The toothed form-fitting structure is applied locally at the torque transmission interface, while the rest of the force transmission means uses simpler clamping structures. This local application of complexity only where necessary reduces overall manufacturing complexity while maintaining effective torque transmission capability.
3Device complexity
If the force transmission is concentrated at one point, then the connection simplicity is improved, but the stability decreases due to stress concentration
Solution Approach 1:
The single point force transmission is segmented into two spatially separated connection points: a form-fitting connection for torque and a clamping connection for axial forces. This segmentation distributes stress across multiple locations, preventing stress concentration while maintaining connection simplicity through standardized connection elements.
Solution Approach 2:
The force transmission is extended from a single-point (0D) connection to a distributed multi-point (1D/2D) connection along the axle tube. By spacing the form-fitting and clamping connections at different locations, the stress is distributed along the longitudinal dimension, improving stability without significantly increasing complexity.
Data Source
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AI summary
The invention relates to an axle for a commercial vehicle comprising an axle tube (10) and at least one axle link (20) connected to the axle tube (10) by at least one force transmission element (30). The invention is characterized in that the force transmission element (30) is connected to the axle tube (10) by a positive locking connection (15) for transmitting torque and by a clamping connection (16) for transmitting a normal force, wherein the positive locking connection (15) and the clamping connection (16) are arranged spaced apart from each other in the longitudinal direction of the axle tube (10). Furthermore, the invention relates to an axle assembly and a commercial vehicle with such an axle.