Chassis Shell Projections for Axle Body Engagement
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Solution Overview
Problem
Existing commercial vehicle chassis designs fail to effectively absorb and transmit forces in both the longitudinal and circumferential directions, particularly during hard braking, due to inadequate connections between the axle body and axle link.
Innovation Solution
A shell with projections on both the inside and outside surfaces is used to create a form-fitting engagement with the axle body and axle link, providing additional support and stability through material-displacing interactions, and optionally with other chassis components, to enhance force absorption and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a shell is supported directly on the axle body with projections for material-displacing engagement, then the connection strength and form fit are improved, but the device complexity increases due to additional engagement features
Solution Approach 1:
The shell is provided with projections on specific local areas (inside surface engaging with axle body, outside surface engaging with axle link) rather than uniform engagement throughout. This localized engagement approach strengthens critical connection points while maintaining simplicity in non-critical areas.
Solution Approach 2:
The shell acts as an intermediary component between the axle body and axle link, providing form-fitting engagement through projections on both surfaces. This mediator approach creates a positive mechanical connection without requiring complex fastening mechanisms.
2Force
If projections are formed on both inside and outside surfaces of the shell, then the force absorption capability in multiple directions is improved, but the manufacturing complexity increases
Solution Approach 1:
The engagement features are segmented into distinct projection elements on the inside surface and outside surface of the shell. This segmentation allows each set of projections to be optimized for its specific engagement direction while simplifying the overall manufacturing process through modular feature design.
Solution Approach 2:
The material properties of the shell are selected to enable material-displacing engagement, where the shell material is sufficiently hard to engage with the softer axle body and axle link materials. This parameter change in material selection allows the projections to function effectively without complex manufacturing processes.
3Reliability
If the shell is made of hard material for material-displacing engagement, then the engagement reliability is improved, but the ease of manufacture decreases due to material selection constraints
Solution Approach 1:
The material parameters of the shell are specifically selected to be harder than the axle body and axle link materials, enabling reliable material-displacing engagement. This parameter change in material hardness ensures consistent form-fitting connection while working with conventional manufacturing processes.
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 shell design ensures clear positioning and optimal absorption of forces and moments, particularly during hard braking, by engaging projections on both surfaces, thereby enhancing the overall stability and performance of the chassis components.
Implementation Method 1
projections formed on the inside engage in the outside of the axle body in a material-displacing manner
Implementation Method 2
roughened support areas that are produced using a laser beam process. As a result, the support areas have projections in the form of material tips of such hardness that these material-displacing engage
Implementation Method 3
rapid cooling causes the tips to harden
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
A chassis for a commercial vehicle is proposed, comprising an axle body (1) extending transversely to the longitudinal direction of the vehicle, a control arm (5) extending substantially in the longitudinal direction of the vehicle, and at least one shell (10, 110) between the axle body (1) and the control arm (5). This shell has an outer surface (12) facing the control arm (5) and an inner surface (11) facing the axle body (1). The inner surface (11) is supported under compressive load directly against the outer surface (20) of the axle body (1), with projections formed on the inner surface (11) of the shell (10, 110) engaging into the outer surface (20) of the axle body (1) by displacing material. To prevent relative movements, including those in the circumferential direction, between the chassis components connected by clamps, further projections are formed on the outer surface (12) of the shell (10, 110).The further projections engage in a material-displacing manner in a surface on the axle link (5) or on a component (9) supported against the axle link (5). Furthermore, a corresponding shell (10) and a corresponding shell pair (10, 110) are proposed.