Composite Axle Suspension System Weight Reduction
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Solution Overview
Problem
Existing suspension systems for trucks and trailers are labor-intensive and time-consuming to manufacture, making them unsuitable for achieving the desired weight reduction and increased load-carrying capacity.
Innovation Solution
A composite axle suspension system is developed using a composite material for the axle portion, with metal beams and spindles attached via sleeves or direct bonding, employing pultrusion for manufacturing to reduce weight while maintaining strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional metal axles are used in suspension systems, then strength and load-carrying capacity are ensured, but weight is excessive leading to increased fuel consumption
Solution Approach 1:
The patent applies composite materials (specifically pultruded composite sections) to manufacture the entire axle assembly, replacing traditional metal axles. This resolves the contradiction by providing a material that offers both reduced weight and sufficient strength for load-carrying requirements, directly addressing the fuel efficiency goal while maintaining structural integrity
2Weight of moving object
If composite materials are used to reduce weight, then fuel consumption decreases, but manufacturing complexity and labor intensity increase
Solution Approach 1:
The patent segments the axle assembly into distinct functional components (axle tube, leaves, brake components, suspension elements) that can be separately manufactured and then assembled. This resolves the manufacturing complexity issue by allowing each component to be optimized independently while using standardized composite manufacturing processes like pultrusion
Solution Approach 2:
The patent changes the manufacturing parameters by adopting pultrusion technology, which is a continuous, automated process that extrudes composite materials through a die. This parameter change from traditional labor-intensive composite fabrication to automated pultrusion significantly reduces labor intensity while maintaining weight reduction benefits
3Weight of moving object
If labor-intensive composite fabrication methods are used, then weight reduction is achieved, but production time and cost increase
Solution Approach 1:
The patent transforms the manufacturing approach by implementing automated pultrusion processes with continuous production capabilities. This parameter change from batch, labor-intensive fabrication to continuous automated extrusion dramatically increases productivity while maintaining the weight reduction achieved through composite materials
Solution Approach 2:
The patent incorporates preliminary design of integrated composite sections that combine multiple functional elements into single pultruded components. This preliminary integration reduces the number of separate manufacturing operations and assembly steps required, thereby increasing overall manufacturing efficiency and productivity
Data Source
AI summary
A suspension system having an axle, at least a portion of which is made of a composite material. In a described embodiment, a suspension system includes an axle assembly which has a composite axle portion. Metal spindles are attached at each end of the axle for mounting wheels thereto. Two beams may be attached directly to the composite axle portion, to a sleeve overlying the composite axle portion, or to an axle seat attached to the sleeve or directly to the composite axle portion.