Hollow Steer Axle Design for Weight Reduction
Solution Overview
Problem
Conventional forged I-beam steer axles for vehicles require substantial material, leading to increased weight and cost, necessitating a design that reduces material usage while maintaining functionality.
Innovation Solution
A substantially hollow steer axle with a three-sided central portion and curvilinear end portions, featuring first and second spring seats, plates, and angled spring pads, which are secured using mechanical fasteners and welding, allowing for a more efficient use of material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a forged I-beam structure is used for the steer axle, then structural strength and reliability are maintained, but material usage increases leading to higher weight and cost
Solution Approach 1:
The steer axle is divided into multiple functional segments: a hollow tubular main body, separate spring seats, plates, and spring pads. This segmentation allows each component to be optimized independently for strength-to-weight ratio, eliminating the need for a solid I-beam structure while maintaining overall structural integrity.
Solution Approach 2:
The main body of the steer axle uses a hollow tubular structure instead of a solid I-beam. This thin-walled tubular design provides sufficient structural strength and stiffness while dramatically reducing material usage and weight compared to traditional solid forged I-beam construction.
2Stability of the object's composition
If a forged I-beam structure is used for the steer axle, then structural integrity is maintained, but material cost increases
Solution Approach 1:
By segmenting the axle into a tubular body with separate attached components (spring seats, plates, pads), the design uses material only where structurally necessary. This eliminates redundant material in non-critical areas while maintaining integrity in load-bearing regions.
Solution Approach 2:
The steer axle employs a composite construction combining a hollow tubular structure with separately attached spring seats, plates, and spring pads. This composite approach optimizes material distribution, using material strategically only where needed for specific functions, thereby reducing overall material consumption while preserving structural integrity.
3Strength
If traditional I-beam design with flanges is used, then structural strength is achieved, but manufacturing complexity and material cost increase
Solution Approach 1:
The design separates the spring seats and other components as distinct attachable parts rather than integrating them into a complex monolithic I-beam structure. This segmentation simplifies manufacturing by allowing each component to be produced and treated independently, then assembled through welding or other joining methods.
Solution Approach 2:
The invention changes the fundamental geometric parameters from a solid I-beam cross-section to a hollow tubular cross-section. This parameter change simplifies the manufacturing process (requiring less material removal and forming operations) while maintaining or improving structural efficiency through the hollow tube geometry.
Data Source
AI summary
A steer axle for a vehicle and a method of making the same involves forming portions of a steer axle to have a three sided design. Spring seats that wrap around two of the three sides are secured to the steer axle. Plates are secured to the spring seats. The plates extend over the third surface of the steer axle. Angled spring pads are located over the plates.