Bolt-On Payload Extension Kit for Six-Wheel Vehicle Conversion
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Solution Overview
Problem
Current vehicle suspension systems require significant redesign and modifications to the frame, suspension, tires, and driveline to increase payload capacity, which is costly and inefficient, especially when transitioning from a four-wheeled to a six-wheeled variant.
Innovation Solution
A bolt-on payload extension kit that includes a sub-frame extension and suspension assemblies, allowing the addition of two rear wheels without altering the existing chassis, suspension, tires, or driveline, and optionally incorporating a plug-in hybrid electric vehicle (PHEV) hybrid E-axle for the sixth wheel, enabling a six-wheeled variant without major design changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a third axle and third pair of wheels are added to increase payload capacity, then payload capacity is improved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The suspension system is divided into separate, modular assemblies (front suspension assembly, first rear suspension assembly, and second rear suspension assembly) that can be independently designed, manufactured, and installed. This segmentation allows the payload extension kit to be added as a discrete module without redesigning the entire suspension system, thereby increasing payload capacity while managing device complexity.
Solution Approach 2:
The suspension assemblies are designed with universal mounting interfaces and standardized components that can be adapted to different vehicle platforms. The bolt-on architecture allows the same basic assembly design to serve multiple functions across different payload configurations, reducing the need for platform-specific redesigns and lowering manufacturing complexity.
2Quantity of substance
If dramatic changes are made to the chassis and suspension to increase payload capacity, then payload capacity is improved, but ease of manufacture deteriorates
Solution Approach 1:
The payload extension kit is designed as a pre-assembled, bolt-on module that includes all necessary suspension components, frame attachments, and mounting hardware configured in advance. This preliminary preparation allows the kit to be installed as a complete unit without requiring complex on-site assembly or modification of the vehicle chassis, significantly improving manufacturing efficiency.
Solution Approach 2:
The payload extension kit uses standardized, off-the-shelf components and simple bolt-on attachments rather than custom-welded or permanently integrated structures. This approach allows for easier replacement, repair, and modification, reducing manufacturing costs and improving ease of manufacture while maintaining payload capacity.
3Quantity of substance
If the suspension system is redesigned to support higher payload, then payload capacity is improved, but loss of time increases due to extensive modifications
Solution Approach 1:
By segmenting the suspension system into independent assemblies with standardized interfaces, the payload extension can be installed as a discrete module without disrupting the existing vehicle suspension. This eliminates the need for time-consuming chassis modifications and allows for rapid deployment of increased payload capacity.
Solution Approach 2:
The bolt-on payload extension kit acts as an intermediary between the existing vehicle chassis and the additional axle assembly. It provides standardized mounting interfaces and load transfer mechanisms that bridge the original suspension system and the new payload-capable configuration, enabling quick installation without extensive modifications to either the vehicle or the added components.
Data Source
AI summary
A vehicle suspension system may include a first suspension assembly operably coupling a first wheel to a chassis of a vehicle, a second suspension assembly operably coupling a second wheel to the chassis where the first and second wheels form a pair of front wheels, a third suspension assembly operably coupling a third wheel to the chassis, a fourth suspension assembly operably coupling a fourth wheel to the chassis where the third and fourth wheels forming a first pair of rear wheels, and a payload extension kit that is attachable to the chassis non-permanently. The payload extension kit may include a fifth suspension assembly operably coupling a fifth wheel to a sub-frame extension of the payload extension kit, and a sixth suspension assembly operably coupling a sixth wheel to the sub-frame extension, where the fifth and sixth wheels form a second pair of rear wheels.