Commercial Vehicle Crossmember Shackle Mount Integration
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Solution Overview
Problem
Existing cross members for commercial vehicles face challenges in integrating shackle mounts in a space-saving manner without complicating attachment processes, avoiding issues like contact corrosion, thermal expansion, and weakening of the base material, while also optimizing connection and attachment areas.
Innovation Solution
The cross member features integrally integrated shackle mounts within its chords, eliminating the need for separate attachment and allowing for a more efficient design of connection and attachment areas, with reinforcement in the integration areas and load distribution to outer web areas, enabling direct and secure attachment of add-on parts and bumpers without additional tools or welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If shackle mounts are separately attached to the cross member, then the cross member can be assembled in stages, but the attachment process becomes complicated requiring multiple tools, welding work, and is prone to contact corrosion, thermal expansion, and loosening of screw connections
Solution Approach 1:
The shackle mounts are integrally formed with the cross member as a single piece structure. The first and second shackle mounts are directly integrated into the first and second chords respectively, eliminating the need for separate attachment processes. This merging of components resolves the technical contradiction by simultaneously achieving simple manufacture (no separate attachment needed) and high reliability (no welding, screws, or separate fastening elements that could fail)
Solution Approach 2:
The cross member is designed with distinct functional zones: the first and second chords with integrated shackle mounts for add-on part connections, and separate connection areas for bearing blocks and bumper attachments. This segmentation allows each area to be optimized for its specific function without interference from other connection types, resolving the contradiction by providing dedicated attachment zones that are simple and reliable for their intended purposes
2Device complexity
If shackle mounts are integrated into the chords, then the design is simplified and space is saved, but the connection areas and attachment areas must be adequately reinforced to handle loads
Solution Approach 1:
The cross member features localized reinforcement at the integration areas where the shackle mounts connect to the chords. The first chord is reinforced at the first integration area and the second chord is reinforced at the second integration area. This local quality enhancement ensures that the integrated shackle mounts can handle loads without compromising the overall structural simplicity, resolving the contradiction between simplified design and adequate strength
3Adaptability or versatility
If multiple connection areas are provided for different functions, then the cross member is versatile, but the design becomes more complex and space-consuming
Solution Approach 1:
The cross member is segmented into distinct functional zones: first and second connection areas for bearing blocks, first and second attachment areas for bumpers, and first and second integration areas for shackle mounts. Each zone is spatially separated and optimized for its specific function. This segmentation provides versatility for different connection types while maintaining design simplicity through clear functional separation, resolving the contradiction between adaptability and design complexity
Data Source
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AI summary
The invention relates to a crossmember (10), in particular a front crossmember, for a motor vehicle, especially a commercial vehicle. The crossmember (10) has a first strap (12), in particular an upper strap, a second strap (14), in particular a lower strap, and a first shackle receptacle (24) for detachably connecting an attachment (28) to the crossmember (10). The crossmember (10) has a second shackle receptacle (26) for detachably connecting an attachment (28) to the crossmember (10). The first shackle receptacle (24) and the second shackle receptacle (26) are integrally integrated into the first strap (12) and/or the second strap (14).