Chassis Load Switch for Lightweight Overload Detection
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Solution Overview
Problem
Current chassis components for motor vehicles are oversized to ensure reliability and safety, leading to increased mass and costs, particularly in fiber composite constructions, where additional mass contradicts the goal of weight reduction, and existing load detection sensors are not cost-effective.
Innovation Solution
A chassis component with a sensor designed as a switch, featuring a load introduction element and two switching elements, where the switch changes position upon exceeding a load limit value due to bending loads, allowing for cost-effective detection and evaluation of misuse or overload, enabling autonomous monitoring and triggering warnings or safety measures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If chassis components are oversized to ensure reliability and safety, then functional reliability is improved, but mass increases
Solution Approach 1:
The patent applies preliminary action by integrating a load detection sensor into the chassis component before actual use. The sensor continuously monitors bending loads and detects misuse scenarios (such as improper jack placement) before they cause damage. This allows the component to operate at optimal design loads without requiring excessive over-dimensioning, thereby reducing mass while maintaining reliability through real-time monitoring and early warning capabilities.
2Reliability
If additional mass is added to safeguard against misuse scenarios, then safety is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies self-service by implementing an autonomous monitoring system where the chassis component itself detects and reports its own load status. The integrated sensor automatically identifies misuse scenarios and triggers warnings or alerts without requiring external inspection or intervention. This self-monitoring capability enables the use of optimally sized components rather than oversized ones, reducing material costs and manufacturing expenses while maintaining safety through continuous self-verification.
3Weight of moving object
If fiber composite construction is used to reduce weight, then mass is reduced, but additional mass is required to safeguard against misuse
Solution Approach 1:
The patent applies feedback by implementing a closed-loop monitoring system where bending load sensors continuously measure actual loads on the fiber composite chassis component and compare them against safe operating limits. When misuse scenarios are detected (such as excessive bending loads from improper jack placement), the system provides immediate feedback through warnings or alerts. This real-time feedback mechanism allows fiber composite components to be used at their optimal weight without requiring excessive safety margins, as the monitoring system compensates for the reduced inherent robustness of lightweight materials.
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 allows for reliable detection of bending loads, preventing damage and ensuring safety while reducing the need for oversized components, maintaining the lightweight design intent of fiber composite materials and providing a cost-effective monitoring system.
Implementation Method 1
A bending load occurring on the chassis component leads, depending on its magnitude, to its deformation
Implementation Method 2
at least two more elastic switching elements
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a chassis component (3) for a motor vehicle (1), on which at least one sensor (6) for detecting a mechanical load (F) is arranged, wherein the at least one sensor (6) is in the form of a switch (6a, 6b, 6c) of an electric circuit (15), with at least one load introduction element (11) and at least two switching elements (12), wherein the load introduction element (11) has greater rigidity than the at least two switching elements (12), wherein exceeding of a load limit value by a bending load received by the at least one load introduction element (11) via the chassis component (3) causes a change in a switching position of the at least two switching elements (12).