Coreless Haul Truck Frame Node Casting

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional space frame structures for haul trucks face challenges in dynamic applications due to loads, bending, twisting, and flexing, requiring carefully designed high-strength castings and fabrications for appropriate stiffness and flexibility.

Innovation Solution

A coreless center upper frame node connector is provided, comprising a forward horizontal upper frame node, a rearward horizontal upper frame node, a rearward angular upper frame node, a vertical upper frame node, and connection pads, all of which are solid without hollow portions, allowing for efficient weldable attachments to frame tubes and connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional fabricated nodal connections are used in space frames, then the structure can be assembled from separate parts, but the structural integrity and strength under dynamic loads are insufficient

Engineering Contradiction:

Improvestructural integrityVSAvoidfabrication complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges multiple separate fabricated components into a single integrated coreless casting. The node connector combines the central body, multiple frame tube connections, and reinforcement features into one monolithic structure, eliminating the need for assembling separate parts while enhancing structural integrity under dynamic loads.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs composite material construction by integrating different material properties within the coreless casting. The node connector combines high-strength casting material with strategically placed reinforcement features and connection interfaces, creating a composite structure that optimizes both strength and flexibility characteristics.

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If high-strength castings with hollow portions are used, then the weight is reduced, but the structural integrity and load transfer capability are compromised

Engineering Contradiction:

Improvenode connector weightVSAvoidload transfer capability

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent applies the extraction principle by removing hollow portions from the casting and replacing them with solid coreless construction. This eliminates weak points and potential failure zones while maintaining optimized material distribution, thereby improving load transfer capability without excessive weight gain.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent applies local quality by strategically distributing material density within the coreless casting. Instead of uniform solid construction, the design optimizes material placement in specific regions to enhance load transfer paths and structural integrity where needed, while maintaining overall weight efficiency through controlled solidification patterns.

Inventive Principle:

Principle #3Local quality

3Strength

If welded steel frames are used, then the structural strength is sufficient, but the weight becomes extremely heavy and manufacturing requires extensive welding

Engineering Contradiction:

Improveframe strengthVSAvoidframe weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent merges multiple welding operations and separate steel components into a single coreless casting operation. The node connector is produced as one integrated piece through controlled solidification, eliminating the need for extensive welding assembly while maintaining sufficient structural strength for the application.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent substitutes the mechanical welding process with a casting process. Instead of assembling and welding separate steel components, the node connector is formed through controlled solidification of molten material, replacing complex mechanical assembly operations with a more efficient metallurgical process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 coreless center upper frame node connector enhances the structural integrity and flexibility of space frames for haul trucks, enabling effective load transfer and improved performance under dynamic conditions.

Implementation Method 1

configured to weldably attach a first frame tube

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS20250083746A1Space frame kinetic node casting

Publication Date: 2025.03.13 CATERPILLAR INC

AI summary

A center upper frame node connector, which can be a casting, can comprise: a forward horizontal upper frame node oriented in a first forward direction; a rearward horizontal upper frame node oriented in a first rearward direction opposite the first forward direction; a rearward angular upper frame node oriented in a second rearward direction and a first downward direction; a vertical upper frame node oriented in a second downward direction; and a first connection pad on a first side of the upper frame node casting and a second connection pad on a second side on upper frame node connector opposite the first side. The center upper frame node connector can be coreless, that is, without any hollow portions at any of the frame nodes and either of the first and second connection pads.