Captive Spacer Axle Stop for Commercial Vehicle Frame
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Solution Overview
Problem
Commercial vehicles face complexity and increased costs due to the need for various attachment devices with different spacer distances, limiting flexibility and requiring early determination of axle stops, which restricts spring deflection and force dissipation.
Innovation Solution
A modular anchorage device design where the stop surface is formed by the mounting element, allowing for late decision-making on anchorage devices and using extruded profiles for spacers that can be connected form-fittingly, reducing the need for early welding and enabling adjustable ride height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different attachment devices with different spacer distances are provided for various commercial vehicle configurations, then the vehicle can be adapted to different customer requirements and body heights, but the device complexity and production costs increase
Solution Approach 1:
The mounting element is designed with a universal interface that can accommodate different spacer distances. The recess in the mounting element can receive spacers of varying thicknesses, allowing the same mounting element to serve multiple functions for different body heights and configurations, thereby reducing the need for multiple specialized attachment devices
Solution Approach 2:
The attachment device is segmented into modular components: a mounting element, a spacer, and a stop surface. The spacer acts as an independent adjustable component that can be selected in different thicknesses to achieve the required distance between the frame structure and the stop surface, simplifying the overall device while maintaining versatility
2Manufacturing precision
If the axle stop position is determined early in production, then the attachment device can be manufactured with precision, but the flexibility to adjust spring deflection and ride height is reduced
Solution Approach 1:
The attachment device incorporates adjustable elements that allow the stop surface position to be modified after the basic structure is manufactured. The spacer can be selected or adjusted to change the distance between the mounting element and stop surface, enabling dynamic adaptation of spring deflection requirements without compromising manufacturing precision of the base components
Solution Approach 2:
The mounting element is pre-manufactured with a standardized recess structure that is designed to accommodate various spacer configurations. This preliminary preparation of the mounting element with a universal interface allows for precise manufacturing of the base component while preserving flexibility for later adjustment of the exact stop position based on spring deflection requirements
3Reliability
If the spacer is welded to the mounting element, then a secure and durable connection is achieved, but the assembly time and production complexity increase
Solution Approach 1:
The welding process is replaced with a mechanical insertion system where the spacer is fitted into a recess of the mounting element. This mechanical connection achieves sufficient reliability without the time-consuming and complex welding process, thereby improving productivity while maintaining connection security
Solution Approach 2:
The recess in the mounting element acts as an intermediary feature that facilitates the connection between the spacer and the mounting element. This intermediate structure enables a simple snap-fit or interference fit connection that provides reliable mechanical attachment without requiring welding, thus reducing assembly time and production complexity
Data Source
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AI summary
Described and illustrated is a commercial vehicle, in particular a truck, trailer, or semi-trailer, comprising at least one frame structure, at least one axle unit, and at least one mounting device providing a mounting surface for the axle unit. The mounting device includes a mounting element fixed to the frame structure and a spacer provided between the frame structure and the mounting surface. To further reduce the manufacturing costs of the commercial vehicles, the spacer is designed to be captive and positively locked to the mounting element.