Articulating Leaf Spring Mount for Heavy-Load Axle Stress Relief
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Solution Overview
Problem
Existing leaf spring suspensions experience excessive stress due to over-constraint under heavy loads, particularly in vehicles with high leaf spring stacks, leading to reduced articulation and shorter axle housing life.
Innovation Solution
An articulating leaf spring suspension system with a new axle-to-leaf spring mount that introduces limited rotation parallel to the vehicle axis, incorporating rubber bushing components to enhance movement and reduce stress, allowing independent pivoting of the axle housing and spring stack without increasing vehicle height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional rigid axle-to-leaf spring mounting is used, then load-carrying capacity is maintained, but stress on suspension components increases and articulation is reduced
Solution Approach 1:
The patent applies the Dynamics principle by replacing the traditional rigid fixed mounting with an articulating bracket assembly that enables dynamic movement. The bracket allows the axle housing to pivot relative to the leaf spring stack along a rotational axis, transforming the static connection into a dynamic one that adapts to terrain variations and reduces stress during vehicle operation.
Solution Approach 2:
The patent applies the Segmentation principle by dividing the previously monolithic rigid connection into separate functional components: the articulating bracket assembly with its rotational axis, the bushing components for damping, and the leaf spring stack. This segmentation allows each component to perform its specific function independently while working together to reduce stress and improve articulation.
2Reliability
If additional rotational degree of freedom is added to reduce stress, then suspension articulation improves, but device complexity increases
Solution Approach 1:
The patent applies the Merging principle by combining multiple functions into the articulating bracket assembly: it serves as both the mounting structure and the articulation mechanism, while also incorporating bushing components for damping. This integration reduces the need for separate components and simplifies the overall structure despite adding functional capabilities.
Solution Approach 2:
The patent applies the Intermediary principle by introducing the articulating bracket assembly as a mediator between the axle housing and the leaf spring stack. This intermediary component absorbs and manages the complexities of the rotational degree of freedom and stress reduction mechanisms, shielding the rest of the suspension system from these complexities while achieving the desired stress reduction and improved articulation.
3Reliability
If rubber bushing components are added to enhance movement, then stress reduction is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent applies the Parameter changes principle by utilizing the viscoelastic properties of rubber bushing materials to change the mechanical parameters of the suspension system. The bushings provide progressive resistance to movement, allowing easy assembly during installation while providing stress reduction during operation. This material-based solution achieves complex functional requirements through material property selection rather than complex manufacturing processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces stress on suspension components, improves articulation, and extends the life of axle housing by providing additional degrees of freedom, particularly beneficial for heavily loaded vehicles, including armored ones, without compromising load-carrying capacity or on-road handling.
Implementation Method 1
incorporating rubber bushing components to enhance movement and reduce stress
Data Source
AI summary
An articulating leaf spring suspension (ALSS) comprising a bushing assembly and a base component; a first bushing pillar having a first bushing; and a second bushing pillar having a second bushing distally opposed from the base component. The ALSS includes a cap secured to a top of the bushing pillars and extending along the bushing assembly, the cap comprising an arch middle portion between a gap between the first and second bushing pillars, the arch middle portion, the first and second bushing pillars, and the base component forming an opening. The ALSS includes a bracket assembly including a first bracket secured to an exterior surface of the bushings and a second bracket secured to an exterior surface of the bushings. The ALSS includes a leaf spring interface plate disposed below and parallel to the base component and secured to the brackets against a bottom surface of the base component.