Load-Bearing Fluid-Line Axle Link for Lower Unsprung Mass
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Solution Overview
Problem
Existing axle handlebars for vehicle wheel suspensions face challenges in reducing movable mass, especially when accommodating larger steering angles and additional functionalities, which is crucial for vehicles requiring minimal unsprung masses and increased maneuverability.
Innovation Solution
The axle handlebar integrates fluid and electrical lines as mechanically load-bearing parts, utilizing them as part of the load-bearing structure and incorporating them into the topology optimization of the components. This design reduces the need for additional components, minimizes material usage, and leverages additive manufacturing for complex geometries and integrated line systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional axle guide concepts using forged or die-cast parts or thick-walled sheet metal parts are used, then structural integrity is ensured, but moving mass increases and inertial forces increase quadratically with acceleration
Solution Approach 1:
The patent changes the material parameters by using lightweight materials (aluminum, titanium, plastics) instead of conventional heavy materials (steel, cast iron). This parameter change enables weight reduction while maintaining structural integrity through optimized material selection and design
Solution Approach 2:
The patent employs composite construction by combining lightweight materials with strategic reinforcement elements. The hollow chamber profiles with thin walls create a composite structure that achieves high strength-to-weight ratio, integrating multiple material properties in a single component
2Weight of moving object
If hollow chamber profiles with thin walls or lightweight materials are used, then moving mass is reduced, but structural strength and stiffness decrease
Solution Approach 1:
The patent segments the axle guide into hollow chamber profiles with optimized wall thickness distribution. This segmentation allows material to be placed only where structurally necessary, reducing overall mass while maintaining strength through strategic material distribution rather than uniform thick walls
Solution Approach 2:
The patent transitions from two-dimensional planar reinforcement to three-dimensional hollow chamber structures. The volumetric configuration of the hollow chambers provides structural rigidity through spatial geometry rather than relying solely on wall thickness, achieving strength through dimensional optimization
3Area of stationary object
If additional functionalities such as integrated fluid lines and electrical cables are added to the axle guide, then installation space is optimized, but device complexity increases
Solution Approach 1:
The patent merges previously separate components (axle guide body, fluid lines, electrical cables, cable guides) into a single integrated component. The additive manufacturing process enables these elements to be combined in one piece, eliminating the need for separate assembly steps and reducing overall system complexity despite increased functionality
Solution Approach 2:
The axle guide base body is designed as a multi-functional component that simultaneously provides structural support, guides wheels through articulation, routes fluid lines for braking/cooling, and accommodates electrical cables for sensors and actuators. This universal design consolidates multiple functions into one component, optimizing installation space
4Adaptability or versatility
If additive manufacturing is used to produce the axle guide with integrated cable guides, then manufacturing flexibility and integration are improved, but manufacturing precision and void-free uniformity become challenging
Solution Approach 1:
The patent optimizes additive manufacturing parameters including layer thickness, infill density, support structure design, and printing orientation to achieve void-free uniformity. By carefully controlling these manufacturing parameters, the process produces dense, defect-free components with the required precision for load-bearing applications
Solution Approach 2:
The patent incorporates preliminary support structures and optimized printing sequences during the additive manufacturing process to prevent defects before they occur. These preliminary measures ensure proper material deposition, avoid void formation, and maintain dimensional accuracy throughout the complex integrated geometry
Data Source
Figure 1~2a
Figure 2b
Figure 3
AI summary
Axle link for a wheel suspension of a vehicle, comprising an axle link body (1) with at least one first pivot point (2) to a vehicle body and at least one second pivot point (3) to a chassis component pivotable relative to the vehicle body, wherein the axle link body has fluid lines (4, 10) between the at least first and the at least second pivot point, wherein the fluid lines are solely mechanically load-bearing parts of the axle link body at least in a section between the at least first and the at least second pivot point and the fluid lines are limited only by a component of the axle link body.