Curved Twist-Beam Axle Variable Cross Section
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Solution Overview
Problem
Existing twist-beam axles for vehicles face limitations in structural reliability and weight due to the need for reinforcements and lack of localized torsional stiffness enhancement, particularly in four-wheel-drive vehicles, where additional structural elements increase weight and complexity.
Innovation Solution
A curved twist-beam axle with a closed box-type structure and variable cross section, featuring a progressive shape evolution from a central double U to a circular shape, providing increased torsional stiffness at the ends without additional reinforcements, allowing for effective housing of mechanical components and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If triangular reinforcements are welded to the twist beam to increase stiffness and fatigue strength, then the structural reliability is improved, but the device complexity and manufacturing burden increase
Solution Approach 1:
The patent applies local quality by varying the cross-sectional shape along the beam length. The beam transitions from a rectangular cross-section at the ends to a curved/arched cross-section in the central region. This localized geometric modification concentrates stiffness and strength exactly where needed (central region) without adding reinforcements to the entire structure, thereby improving reliability while avoiding increased complexity.
Solution Approach 2:
The patent changes the geometric parameters of the beam cross-section along its length. Specifically, the cross-section curvature radius varies from the ends toward the center, creating a smooth transition that optimizes structural performance. This parameter variation allows the beam to achieve higher stiffness and fatigue strength in critical areas without requiring additional reinforcement elements.
2Strength
If the twist beam structure is oversized to overcome partial lack of sturdiness, then the structural strength is improved, but the weight of the vehicle increases
Solution Approach 1:
The patent implements local quality by concentrating structural reinforcement only in the central region of the beam where it is most needed for strength and stiffness. The end regions maintain a simpler rectangular cross-section, avoiding unnecessary material usage. This localized approach achieves the required structural strength while minimizing weight increase.
Solution Approach 2:
The patent applies curvature to the beam's cross-section in the central region, transitioning from a rectangular to a curved/arched shape. This geometric transformation increases the moment of inertia and section modulus, thereby enhancing bending strength and stiffness without requiring a proportional increase in material quantity, thus improving strength-to-weight ratio.
3Strength
If additional reinforcements are added to increase torsional stiffness at the ends, then the torsional strength is improved, but the weight and complexity of the structure increase
Solution Approach 1:
The patent applies local quality by providing the curved cross-section specifically in the central region of the beam, while the end regions maintain a rectangular cross-section. This localized geometric modification increases torsional stiffness where needed without adding weight to the entire structure, avoiding unnecessary complexity.
Solution Approach 2:
The patent segments the beam into different regions with different cross-sectional characteristics: rectangular cross-section at the ends and curved cross-section in the center. This segmentation allows each region to be optimized for its specific functional requirements, achieving torsional strength enhancement without overall structural oversizing.
4Reliability
If triangular reinforcements are welded to the twist beam, then the fatigue strength is improved, but the manufacturing procedure becomes longer and more burdensome
Solution Approach 1:
The patent merges the reinforcement function directly into the beam's cross-sectional geometry by creating a curved/arched shape. This integrated design eliminates the need for separate triangular reinforcement pieces and their associated welding operations, thereby maintaining fatigue strength while significantly simplifying the manufacturing process.
Solution Approach 2:
The patent changes the cross-sectional geometry parameters from a simple rectangular shape to a curved shape with varying radius. This geometric transformation inherently provides the reinforcement needed for fatigue strength without requiring additional components or complex assembly steps, improving ease of manufacture.
Data Source
Figure 1~3
Figure 4a~5
AI summary
A curved twist-beam axle (1) of a vehicle, constituting a means of mobile constraint between the wheels of the vehicle and its frame. The curved twist-beam axle (1) comprises a beam (2) (2') and a pair of structures (3) designed to be connected each with a respective wheel of the vehicle, via a respective hub, and with shock-absorbing suspension elements of the frame. The beam (2)(2') is constituted by a closed tubular element bent back so as to present a cross section having a substantially U-shaped configuration at least in a region corresponding to a central stretch of the beam (2)(2'), which evolves progressively moving away from the central stretch until it assumes a cross section having a substantially circular configuration at the ends (2a, 2b) of the beam that are connected to said structures (3); the curvature of the beam (2)(2') lies in a plane substantially orthogonal to the ground and to the direction of advance (4) of the vehicle.