Trailer Coupler Assembly with Angled Reinforcement Members
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Solution Overview
Problem
Over-the-road trailers face limitations in load capacity due to the weight of traditional king pin coupler assemblies, which also affect fuel economy when additional capacity is not utilized.
Innovation Solution
A lightweight yet strong coupler assembly design featuring a support frame with L-shaped reinforcement members and strategically positioned gussets, reducing weight while maintaining structural integrity to transmit loads efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional king pin coupler assemblies are used, then structural strength is maintained, but weight increases reducing load capacity and fuel economy
Solution Approach 1:
The support frame is divided into multiple discrete reinforcement members (first pair forming obtuse angle, second pair forming acute angle) rather than using a solid monolithic structure. This segmentation allows material to be placed only where structurally necessary, reducing overall weight while maintaining strength through strategic positioning and angular configuration of individual members.
Solution Approach 2:
Different regions of the coupler assembly have different levels of reinforcement based on local stress requirements. The reinforcement members are positioned and angled to provide concentrated strength at critical load paths while leaving non-critical areas with less material, achieving weight reduction without compromising structural integrity where it matters most.
2Strength
If reinforcement members are added to increase strength, then structural integrity improves, but device complexity increases
Solution Approach 1:
The reinforcement members are configured with asymmetric angular relationships - a first pair forming an obtuse included angle and a second pair forming an acute included angle. This asymmetric arrangement optimizes strength distribution according to actual load patterns while avoiding the complexity of symmetric over-reinforcement, achieving efficient structural integrity with minimized components.
Solution Approach 2:
Multiple reinforcement functions are combined into integrated support frame members that simultaneously provide structural strengthening, load distribution, and geometric bracing. The reinforcement members are positioned to perform multiple structural roles at once, reducing the need for separate components and simplifying the overall device complexity.
Data Source
AI summary
A coupler assembly for a trailer includes a base plate, a king pin assembly coupled to the base plate, the king pin assembly configured to be coupled to a fifth wheel of a tractor, and a support frame coupled to the base plate and configured to brace the king pin assembly. The support frame includes a pair of outboard reinforcement members forming an obtuse included angle therebetween, and a pair of inboard reinforcement members forming an acute included angle therebetween. The pair of inboard reinforcement members are disposed within the obtuse angle formed by the pair of outboard reinforcement members. The obtuse angle formed by the pair of outboard reinforcement members and the acute angle formed by the pair of inboard reinforcement members are each bisected by a longitudinal axis of the trailer.