Leaf Spring Axle Integration via Bifurcated Clamping
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Solution Overview
Problem
Existing leaf spring suspension systems for wheeled vehicles face challenges with increased installation height, weight, complexity, and risk of damage due to the use of clamping devices, which complicate assembly, maintenance, and lead to unsatisfactory stress distribution and structural limitations.
Innovation Solution
A novel suspension design where the leaf spring is secured to the axle through bifurcated upper and lower portions that form a positive locking closure, eliminating the need for clamping devices, allowing for reduced installation height, reduced weight, and homogeneous stress distribution, with the leaf spring being inserted into a space defined by these portions, and a closure element providing additional stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If clamping devices are used to secure the leaf spring to the axle, then the leaf spring position is secured and forces are transmitted, but the device complexity increases, weight increases, and installation height increases
Solution Approach 1:
The invention extracts and eliminates the clamping device from the suspension system by integrating the clamping function directly into the axle structure through bifurcated portions. This removes the separate clamping device components (clamping plates, bolts, elastic pads) while maintaining the essential function of securing the leaf spring to the axle.
Solution Approach 2:
The invention merges the clamping device functions into the axle itself by creating bifurcated upper and lower portions that directly engage with the leaf spring. The axle structure is combined with the clamping and positioning functions, eliminating the need for separate clamping components.
2Reliability
If clamping devices are used to secure the leaf spring to the axle, then the leaf spring position is secured, but the weight of the suspension increases
Solution Approach 1:
The invention extracts and eliminates the clamping device from the suspension system by integrating the clamping function directly into the axle structure through bifurcated portions. This removes the separate clamping device components (clamping plates, bolts, elastic pads) while maintaining the essential function of securing the leaf spring to the axle.
Solution Approach 2:
The invention merges the clamping device functions into the axle itself by creating bifurcated upper and lower portions that directly engage with the leaf spring. The axle structure is combined with the clamping and positioning functions, eliminating the need for separate clamping components.
3Force
If clamping devices are used to secure the leaf spring to the axle, then forces are transmitted, but the stress distribution becomes non-homogeneous and damage risk increases
Solution Approach 1:
The invention applies local quality by creating specific geometric features (rounded surfaces, complementary shapes) at the contact points between the leaf spring and axle portions. The rounded surfaces on the leaf spring mid-section and corresponding features on the bifurcated axle portions ensure localized stress distribution and prevent stress concentration at sharp edges or points.
Solution Approach 2:
The invention achieves homogeneous stress distribution through the complementary geometric shapes of the leaf spring mid-section and the bifurcated axle portions. The rounded surfaces and carefully designed contact areas ensure that forces are distributed evenly across the interface, avoiding localized stress peaks that could lead to damage.
4Reliability
If clamping devices are used to secure the leaf spring to the axle, then the connection is secured, but the installation height increases
Solution Approach 1:
The invention applies the nesting principle by positioning the leaf spring mid-section within the space defined by the bifurcated upper and lower axle portions. The leaf spring is essentially nested between the two axle portions, which provides secure connection while maintaining a compact vertical arrangement that reduces installation height compared to external clamping devices.
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 design simplifies assembly, reduces weight and complexity, and ensures homogeneous stress distribution, minimizing the risk of damage to the leaf spring while allowing for efficient force transmission, thereby improving the overall performance and reliability of the suspension system.
Implementation Method 1
The rounded surfaces form a positive locking closure with one another
Implementation Method 2
A layer of elastomer material, which is bonded to the leaf spring, is arranged between the leaf spring and the respective clamping element
Implementation Method 3
forces acting in the direction of the X-axis can be absorbed by means of a (where applicable indirect) substance-to-substance bond and/or a non-positive locking closure between the leaf spring and the axle
Data Source
AI summary
A suspension for a wheeled vehicle include an axle with a mid-section and an end comprising an upper portion and a lower portion defining a space therebetween, a leaf spring having forward and rear ends attached to vehicle structure and a mid-section retained in the space and secured between the upper and lower portions, and a closure element attached to the axle end and at least partially closing an outboard end of the space. The upper and lower axle portions may be formed integrally with the axle mid-section or may be a separately-formed component secured to the axle. The space tapers from a greater vertical dimension at the outboard end thereof to a smaller vertical dimension at an inboard end thereof, and the leaf spring mid-section is wedged into the space. An intermediate element is disposed between the mid-section and at least one of the upper and lower axle portions.