Space Frame Haul Truck Node Casting for Load Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional haul truck designs face challenges with load support point reliability due to manufacturing variations and dynamic loads, particularly in vehicular applications like off-highway terrain, where traditional welded steel frames are heavy and inefficient, and nodal connections in space frames may not adequately address bending and flexing.
Innovation Solution
A dump body pivot pin, suspension node, and rear frame connection system featuring a seven-point casting configuration with specific geometric orientations and connections, including pivot pin bosses, suspension connection bosses, and beam members, to provide a lightweight, durable, and flexible support structure for haul trucks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional welded steel frames are used, then strength and load support are improved, but weight increases significantly
Solution Approach 1:
The frame is divided into multiple tubular members arranged in a space frame configuration, where each tube contributes to the overall structural strength. This segmentation allows the load to be distributed across multiple lightweight elements rather than requiring a single heavy welded steel structure, resolving the contradiction between strength and weight.
2Weight of moving object
If fabricated nodal connections are used in space frames, then weight is reduced, but reliability under dynamic loads deteriorates
Solution Approach 1:
Multiple tubular members are merged into a single integrated casting at the nodal connection points. This combining of multiple tubes into one monolithic structure eliminates the reliability issues of assembled connections while maintaining the weight advantages of space frame design, as the integrated casting removes the need for additional fasteners and assembly steps.
Solution Approach 2:
The nodal connections utilize composite material construction, combining multiple tubular members into a unified casting structure. This composite approach creates a reliable connection that can handle dynamic loads while maintaining the lightweight characteristics of the space frame design.
3Reliability
If multiple load paths are reinforced, then reliability is improved, but device complexity increases
Solution Approach 1:
Multiple load-bearing functions are merged into single integrated castings at the nodal connections. Instead of reinforcing multiple separate load paths with additional components, the design combines these functions into unified structures, reducing overall complexity while maintaining reliability.
Data Source
AI summary
A dump body pivot pin, suspension node, and rear frame connection comprises a dump body pivot pin boss, a rear suspension connection boss, outer and inner upper rear frame tube connection bosses, outer and inner lower rear frame tube connection bosses, upper and lower beams, a beam connection web, and a support tube connection boss. The dump pivot pin boss has a pivot bore, a pin bore center axis, and inner and outer flat surfaces. The rear suspension connection boss includes a suspension connection center axis and inner and outer flat surfaces. The upper beam connects the outer and inner upper rear frame tube connection bosses to the dump body pivot pin boss. The lower beam connects the outer lower rear frame connection boss to the rear suspension connection boss and the dump body pivot pin boss and the inner lower rear frame tube connection boss to the dump body pivot pin boss.