Utility Vehicle Cross Member Assembly with Air Spring Holders
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Solution Overview
Problem
Existing cross member assemblies for commercial vehicles do not efficiently achieve space-saving suspension and damping of rigid axles while maintaining structural stability and minimizing weight and production costs.
Innovation Solution
A cross member assembly featuring air spring holders on the outer sides of longitudinal frame members connected by a connecting element with bridge parts and a central part, utilizing high-strength steel and shear-resistant screw connections, along with optional reinforcement elements, to optimize force transmission and reduce deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a traditional solid cross member assembly is used, then structural stability is ensured, but weight increases and space for rigid axle is reduced
Solution Approach 1:
The cross member assembly is divided into multiple separate components: left and right longitudinal frame members, connecting elements, transverse supports, and reinforcement elements. These segmented components are connected through fastening means rather than forming a solid monolithic structure, reducing overall weight while maintaining structural integrity through strategic placement and connection of individual elements.
Solution Approach 2:
The assembly combines different material properties and structural forms - longitudinal frame members made of high-strength steel, connecting elements with U-shaped profiles, and reinforcement elements that can be welded or fastened. This composite approach allows optimization of each component for its specific function while achieving overall structural stability with reduced weight.
2Stability of the object's composition
If cross members are added to connect longitudinal frame members, then structural stability improves, but available space over the rigid axle decreases
Solution Approach 1:
The connecting elements are positioned and oriented to provide structural connection in three-dimensional space rather than requiring planar placement. The U-shaped profiles and spatial arrangement of components allow the assembly to achieve frame stability while minimizing the horizontal footprint over the rigid axle, preserving valuable space in the critical undercarriage area.
Solution Approach 2:
Reinforcement is applied locally only where structurally necessary - at connection points between longitudinal frame members and connecting elements, and at specific reinforcement positions along the assembly. This localized reinforcement approach maintains frame stability without requiring continuous cross members that would occupy excessive space over the rigid axle.
3Strength
If high-strength steel and reinforcement elements are used, then load capacity increases, but production costs increase
Solution Approach 1:
The assembly is segmented into modular components that can be manufactured separately using standard production processes and then assembled. This segmentation allows high-strength steel to be used only in critical load-bearing areas rather than throughout the entire structure, reducing material costs while maintaining load capacity. The modular nature also simplifies manufacturing and assembly operations.
Solution Approach 2:
The design utilizes different steel grades and thicknesses optimized for specific functional requirements rather than uniformly applying high-strength steel throughout. Connecting elements with U-shaped profiles and strategically placed reinforcement elements provide necessary load capacity while controlling material costs through parameter optimization of each component.
4Force
If multiple connection points and reinforcement elements are added, then force transmission is optimized, but device complexity increases
Solution Approach 1:
The connecting elements with U-shaped profiles serve multiple functions simultaneously: they connect longitudinal frame members, provide attachment points for transverse supports, and incorporate reinforcement features. The fastening means are designed to handle multiple loading conditions (tension, compression, shear) with a single connection mechanism, reducing the number of different component types needed and simplifying the overall assembly process.
Data Source
Figure 1
Figure 2
AI summary
The motor vehicle chassis has longitudinal beams (1) on which are mounted the upper suspension supports (2) for the air spring struts of the suspension. The supports are connected by a cross coupling with a middle beam (4) and two bridging pieces (5) for direct connection to the upper supports. The bridging pieces are connected at their middle sections to the supports and also to the lower flange (6) of the longitudinal beam. Claims include a use and method of production for the suspension.