Heavy-Duty Axle Connection Using Interlocking Sleeve Depressions

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Solution Overview

Problem

Heavy-duty vehicle axle and crossbrace suspension systems face durability issues due to stress risers and mechanical property changes caused by welds, leading to reduced life expectancy and increased weight.

Innovation Solution

The implementation of a mechanical lock at the axle-to-beam and crossbrace-to-beam connections using depressions in the sleeve and axle/crossbrace, eliminating the need for welds and reducing stress risers, with optional supplemental welding at the outboard end for additional support.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welds are used to connect the axle to the beam, then the connection strength is improved, but stress risers and localized mechanical property changes occur in the axle, reducing durability

Engineering Contradiction:

Improveconnection strengthVSAvoidaxle durability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

A sleeve is introduced as an intermediary component between the axle and beam. The sleeve is welded to the beam but uses a mechanical lock (depressions) to attach to the axle, thereby mediating the connection and preventing welds from directly contacting the axle, thus eliminating stress risers on the axle while maintaining connection strength

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The welding process is replaced with a mechanical locking system using depressions that interlock the sleeve and axle. This substitution eliminates the harmful thermal and mechanical effects of welding on the axle while providing sufficient connection strength through the mechanical interlock

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If welds are used to connect the crossbrace to the beam, then the connection strength is improved, but stress risers and localized mechanical property changes occur in the crossbrace, reducing durability

Engineering Contradiction:

Improveconnection strengthVSAvoidcrossbrace durability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

A sleeve is introduced as an intermediary component between the crossbrace and beam. The sleeve is welded to the beam but uses a mechanical lock (depressions) to attach to the crossbrace, thereby mediating the connection and preventing welds from directly contacting the crossbrace, thus eliminating stress risers on the crossbrace while maintaining connection strength

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The welding process is replaced with a mechanical locking system using depressions that interlock the sleeve and crossbrace. This substitution eliminates the harmful thermal and mechanical effects of welding on the crossbrace while providing sufficient connection strength through the mechanical interlock

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If welds are eliminated from the axle, then stress risers and localized mechanical property changes are reduced, improving durability, but alternative connection methods are required to maintain connection strength

Engineering Contradiction:

Improveaxle durabilityVSAvoidconnection strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The sleeve acts as an intermediary that carries the welding load away from the axle. By welding the sleeve to the beam and mechanically locking the sleeve to the axle, the connection strength is maintained while the axle remains free of welds, preserving its durability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The welding connection between axle and beam is replaced with a mechanical locking system using interlocking depressions. This mechanical substitution provides sufficient connection strength without the need for welds on the axle, thereby maintaining both strength and durability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution enhances the durability and life expectancy of the axle and crossbrace connections, potentially reducing material and weight while maintaining strength, and eliminates tolerance issues in alignment and contact.

Implementation Method 1

the sleeve is plastically deformed and the crossbrace is elastically deformed when the sleeve is mating secured to the crossbrace

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 2

the sleeve is plastically deformed and the crossbrace is elastically deformed when the sleeve is mating secured to the crossbrace

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 3

a weld laid between the crossbrace and the sleeve

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS9193236B2Heavy-duty vehicle axle-to-beam or crossbrace-to-beam connection

Publication Date: 2015.11.24 HENDRICKSON USA LLC

AI summary

An axle-to-beam or crossbrace-to-beam connection for a vehicle axle/suspension system includes an axle or crossbrace having at least one depression formed therein. A sleeve is formed with at least one depression and disposed about the axle or crossbrace so that the axle or crossbrace depression and the sleeve depression matingly engage one another to form a mated pair of depressions. A method of forming the axle-to-beam or crossbrace-to-beam connection includes providing an axle or crossbrace and disposing a sleeve about the axle or crossbrace. At least one mated pair of depressions is simultaneously formed in the axle or crossbrace and the sleeve. The sleeve is immovably mounted to a vehicle axle/suspension system.