Axle Support Double-Shell Cross Member Design
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Solution Overview
Problem
Conventional vehicle axle supports face challenges in optimizing rigidity, strength, and installation space, particularly with the integration of additional components like electric drives, due to limited space and complex component accommodation.
Innovation Solution
A double-shell cross member design for the axle support, allowing a hollow cavity for housing axle steering components and power electronics, with non-destructive connections for easy assembly and maintenance, and a plate-shaped shear panel for enhanced accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the axle support uses a solid cross member structure, then strength and rigidity are sufficient, but installation space for additional components is limited
Solution Approach 1:
The cross member is segmented into two separate shell elements that are connected non-destructively. This segmentation creates a hollow interior space within the cross member structure, providing installation space for additional components while maintaining the external dimensions and load-bearing capacity of the original solid cross member.
Solution Approach 2:
The hollow interior space of the cross member is utilized to nest additional components such as electric drives, power electronics, or axle steering components within the existing structure. This nesting approach maximizes space utilization without increasing the overall vehicle footprint or compromising structural integrity.
2Volume of moving object
If the cross member is designed as a hollow structure, then space utilization improves, but rigidity and strength may be compromised
Solution Approach 1:
Material is extracted from the interior of the cross member to create a hollow cavity, but the external shell structure is maintained with sufficient thickness and reinforcement to preserve rigidity and strength. The shell elements are designed with optimized wall thicknesses to balance space creation with structural requirements.
Solution Approach 2:
The cross member shells may utilize composite material constructions that provide high strength-to-weight ratios and enhanced rigidity despite the hollow interior. This allows the structure to maintain or improve mechanical properties while accommodating internal components.
3Strength
If the cross member shells are permanently bonded, then structural integrity is maximized, but maintenance and component replacement become difficult
Solution Approach 1:
The connection between shell elements transitions from a static permanent bond to a dynamic reversible connection. Non-destructive connection methods such as threaded fasteners, bayonet connectors, or interlocking mechanisms with locking features allow the shells to be securely assembled during manufacturing while enabling easy disassembly for maintenance, inspection, or component replacement without damaging the shells or connection elements.
Data Source
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AI summary
An axle support for a vehicle has a left longitudinal member for fastening a left wheel suspension, a right longitudinal member for fastening a right wheel suspension, and at least one cross member connecting the longitudinal members. The cross member is formed by two shells placed on top of each other. The two shells are detachably interconnected in a non-destructive manner. At least one component of an axle steering system is installed in the hollow space between the two shells.