Internal Suspension Rail Bracing for Lightweight Snowmobile Stiffening
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Solution Overview
Problem
Existing snowmobile suspension rail braces are externally mounted, adding weight and requiring hardware, which increases drag and visibility, and do not provide continuous support along the rail's length.
Innovation Solution
An internal bracing system comprising tubular housings with varying cross-sections that fit within the suspension rail cavity, providing continuous support without external hardware, using materials like aluminum or titanium for strength and rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If external braces are mounted to the suspension rail, then strength and durability are improved, but weight increases
Solution Approach 1:
The bracing element is nested inside the suspension rail cavity, with the external bracing profile fitting within the internal cavity of the rail. This eliminates the need for external mounting while providing continuous internal support, reducing overall weight by removing external hardware and mounting structures.
Solution Approach 2:
The bracing function is extracted from an external mounting configuration and relocated to an internal position within the suspension rail. This extraction eliminates the need for external fasteners and mounting hardware, reducing weight while maintaining or improving structural support.
2Strength
If external braces with mounting hardware are used, then bend resistance is improved, but device complexity increases
Solution Approach 1:
The mounting hardware is completely extracted from the system by relocating the bracing element inside the suspension rail cavity. The bracing element is retained solely by the fit between its external bracing profile and the rail's internal cavity, eliminating all fasteners, bolts, and mounting mechanisms.
Solution Approach 2:
The bracing element self-retains within the suspension rail through the interference fit between its external profile and the internal cavity. The geometry of the bracing element itself provides the retention mechanism, eliminating the need for separate mounting hardware and simplifying the overall system.
3Strength
If multiple rivets are used to couple external braces, then structural support is improved, but manufacturing precision requirements increase
Solution Approach 1:
The rivet coupling system is extracted and replaced by a continuous internal bracing profile that fits within the suspension rail cavity. This eliminates the need for multiple discrete fastening points and their associated precision requirements, while providing continuous structural support along the rail length.
Solution Approach 2:
The discrete rivet connection points are merged into a continuous bracing profile that extends along the suspension rail. This continuous internal support structure provides uniform structural reinforcement without the need for multiple precisely spaced fasteners, reducing manufacturing complexity.
4Stability of the object's composition
If external braces are mounted on opposing sides, then stability is improved, but visibility and drag increase
Solution Approach 1:
The bracing element is nested inside the suspension rail cavity, making it invisible from the exterior and eliminating aerodynamic drag. The internal positioning maintains structural stability while removing the harmful effect of external protrusions interacting with airflow.
Solution Approach 2:
The bracing function is extracted from external mounting and relocated to the internal cavity of the suspension rail. This extraction eliminates the visible external braces and their associated aerodynamic drag, while the internal bracing profile continues to provide necessary structural support.
Data Source
AI summary
A device and method for internal bracing and stiffening of a suspension rail for a snowmobile with a housing for installation within a cavity of the suspension rail and having an upper surface, lower surface, and opposing side surfaces extending along a length of the housing. At least one of the upper surface and opposing side surfaces are configured to directly contact an inner surface of the suspension rail when the housing is installed within the interior of the suspension rail. The length of the housing is equal to or less than a length of the interior of the suspension rail. The housing has dimensions sufficient to allow the housing to fit within the interior of the suspension rail without lateral or vertical movement therein. The housing is secured within the interior of the suspension rail without hardware for fastening or coupling the housing to the interior of the suspension rail.