Cast Load Cell Assembly for Low-Profile Fifth Wheel Weighing
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Solution Overview
Problem
Conventional load cell assemblies for vehicles, particularly fifth wheel trailer systems, are labor-intensive and expensive to manufacture, and their integration often results in an unacceptable height increase, making them unsuitable for use with certain configurations like the SAF-Holland sliding fifth wheel mounting system.
Innovation Solution
A cast load cell assembly with a mounting plate, load sensing portion, and shaft mounting portion formed as a unitary, low-profile, weld-free cast member, which includes a flexure gap and sensor cavity to accommodate load sensors without increasing the overall height, allowing for accurate load measurement without the need for welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional precision-machined load cell bodies are used, then measurement precision is improved, but manufacturing cost and labor intensity increase
Solution Approach 1:
The patent combines multiple components (mounting plate, load sensing portion, shaft mounting portion) into a single unitary cast member, eliminating the need for separate precision machining operations and welding assemblies, thereby reducing manufacturing complexity while maintaining measurement precision
Solution Approach 2:
The patent uses a cast construction method that is simpler and less expensive than precision machining, accepting that the load cell may have reduced service life or require replacement rather than investing in complex manufacturing processes
2Measurement precision
If conventional load cell assemblies are integrated into fifth wheel systems, then load measurement capability is improved, but overall height increases making them unsuitable for certain configurations
Solution Approach 1:
The patent redistributes the load cell components in three-dimensional space, positioning the shaft mounting portion above the flexure gap and the sensor cavity above the flexure gap, creating a low-profile configuration that reduces overall height while maintaining functional separation of components
Solution Approach 2:
The patent nests the sensor cavity within the load sensing portion structure, and positions the shaft mounting portion above the flexure gap, creating a compact nested arrangement that minimizes the overall height of the assembly
3Measurement precision
If conventional load cell assemblies are used, then load measurement is achieved, but welding and assembly complexity increase
Solution Approach 1:
The patent merges the mounting plate, load sensing portion, and shaft mounting portion into a single unitary cast member, eliminating the need for welding or bolting these components together, thereby reducing assembly complexity while maintaining the functional integrity required for accurate load measurement
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
The cast load cell assembly provides a cost-effective, low-profile solution for load measurement in fifth wheel trailer systems, reducing manufacturing complexity and avoiding height increases that would prevent trailer use on standard infrastructure.
Implementation Method 1
a flexure gap between the mounting plate and the load sensing portion that allows the sensing portion to move relative to the mounting plate in response to a load on the load sensing portion
Data Source
AI summary
A cast load cell comprising a load sensing portion integrally cast with a first mounting portion. The load sensing portion has a flexure portion spaced apart from the first mounting portion by a flexure gap. The load sensing portion has at least one sensor cavity above at least a portion of the flexure gap. A second mounting portion is integrally cast with the load sensing portion above the flexure gap. A load sensor is connected to the load sensor portion and positioned within the sensor cavity above a portion of the flexure gap. The first mounting portion, the load sensing portion, and the second mounting portion define an integral, low-profile, weld-free, substantially homogenous unitary cast member.