Chassis Load Switch for Axial Overload Detection
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Solution Overview
Problem
Chassis components in motor vehicles face challenges in detecting mechanical loads, particularly axial tensile and compressive forces, which can lead to fatigue and damage, necessitating oversized designs to ensure safety and reliability, resulting in increased mass and cost, especially in fiber composite constructions.
Innovation Solution
A chassis component with at least two load application areas connected by a section, featuring a sensor designed as an electrical switch with load introduction elements and switching elements that change position in response to load limits, allowing for autonomous detection and signaling of overload conditions, enabling early warning and preventive measures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If chassis components are oversized to ensure safety and reliability during maintenance intervals, then functional reliability is improved, but mass increases
Solution Approach 1:
The patent applies preliminary action by implementing a sensor system that continuously monitors chassis components before failure occurs. The sensor detects mechanical loads and sends signals to a control unit, enabling early warning and preventive maintenance. This allows the use of optimally sized components rather than oversized ones, reducing mass while maintaining reliability through proactive monitoring.
2Reliability
If chassis components are oversized to safeguard against misuse scenarios, then safety is improved, but mass increases
Solution Approach 1:
The patent implements feedback by using sensors to continuously monitor the actual mechanical loads on chassis components and transmitting this information to a control unit. The system provides real-time feedback on component status, enabling detection of misuse scenarios (such as improper jack placement or wheel-on-curb events) without requiring oversized components. This allows safety through active monitoring rather than passive over-engineering.
3Weight of moving object
If fiber composite construction is used to reduce mass, then weight is reduced, but detection of mechanical loads becomes more difficult
Solution Approach 1:
The patent applies the intermediary principle by introducing a sensor system as a mediator between the fiber composite chassis component and the monitoring system. The sensor (such as a strain gauge or piezo element) is integrated into the plastic portion of the chassis component and converts mechanical loads into electrical signals. This intermediary enables effective detection of mechanical loads in fiber composite construction without compromising the weight reduction benefits.
4Measurement precision
If sensors are integrated into fiber composite chassis components, then detection capability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies merging by integrating the sensor directly into the plastic portion of the chassis component during the molding process. The sensor is embedded within the composite structure, combining the structural and sensing functions into a single integrated component. This reduces the number of separate parts and assembly steps, thereby reducing manufacturing complexity while maintaining detection capability.
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 provides a cost-effective means to detect axial loads, preventing damage by triggering warnings or halting vehicle operation when load limits are exceeded, thus ensuring safety and extending the service life of chassis components without the need for oversized designs, maintaining the lightweight construction intent.
Implementation Method 1
exceeding a load limit value by a load absorbed by the at least two load introduction elements causes a change in the switching position of at least two mutually corresponding switching elements
Data Source
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AI summary
The invention relates to a chassis component (3) for a motor vehicle, comprising at least two load introduction regions (7) which are connected to one another by means of a connecting section (8), wherein at least one sensor (6) for detecting a mechanical load is arranged on the chassis component (3), wherein the at least one sensor (6) is designed as a switch (6a, 6b, 6c) of an electrical circuit (20), having at least two load introduction elements (11a, 11b), on each of which at least one switching element (12, 12a, 12b, 12c) is arranged, which switching elements can be transferred into an open and a closed switching position, wherein in each case one load introduction element (11a, 11b) is connected to one of the load introduction regions (7), by means of which a load acting in an axial direction of the connecting section (8) can be transmitted to the respective load introduction element (11, 11a, 11b), wherein an overshooting of a load threshold value by a load received by the at least two load introduction elements (11a, 11b) causes a change in a switching position of at least two switching elements (12, 12a, 12b, 12c) that correspond with one another.