Leaf Spring Clamp Group Alignment for Round Axle Stability
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Solution Overview
Problem
Existing suspension systems with clamp groups that mount a leaf spring to a round axle face challenges in maintaining a fixed attachment under various forces and loads, particularly in resisting lateral movement and rotation.
Innovation Solution
The solution involves a clamp group mounting system that includes a locator ring welded to the top of the round axle, which helps resist lateral and rotational movement by aligning components during assembly and distributing forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a heavy welded wrap or bulky welded brackets are used to rigidly connect the spring to the round axle, then the connection strength and resistance to lateral movement and rotation is improved, but the unsprung weight increases significantly
Solution Approach 1:
The connection system is divided into separate functional components: a clamp group with friction surfaces for lateral resistance, and alignment features (locator ring and locator element) for rotational resistance. This segmentation allows each component to be optimized independently, achieving strong connection without excessive weight.
Solution Approach 2:
The alignment features act as intermediaries between the clamp group and the round axle. The locator ring welded to the axle and the locator element in the spring work together to prevent rotation, allowing the clamp group itself to remain lightweight while still achieving rigid connection through the combined action of friction and alignment features.
2Ease of manufacture
If a bolted connection relying on compression and friction is used to connect the clamp group to the round axle, then the ease of assembly and disassembly is improved, but the resistance to rotation about the axle deteriorates
Solution Approach 1:
The solution merges two connection mechanisms: a bolted clamp group providing friction-based lateral resistance and easy assembly, combined with welded alignment features (locator ring and locator element) providing rotational resistance. This combination allows the bolted connection to remain simple while the welded alignment features compensate for the rotational instability.
Solution Approach 2:
The alignment features serve as intermediaries that transfer and resist rotational forces between the clamp group and the round axle. By placing these features at strategic locations, rotational loads are intercepted before they can cause the clamp group to rotate, allowing the bolted connection to maintain its simplicity.
3Stability of the object's composition
If alignment features are added to the clamp group mounting system, then the resistance to lateral movement and rotation is improved, but the device complexity increases
Solution Approach 1:
Instead of making the entire clamp group complex, alignment features are added only at specific locations where they are most effective. The locator ring is welded at one location on the axle, and the locator element is positioned in the spring at the corresponding location. This localized approach provides rotational resistance without requiring complex mechanisms throughout the entire assembly.
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 configuration provides a lightweight, securely mounted assembly that effectively handles forces attempting to move the spring and clamp group relative to the round axle, enhancing stability and reducing unsprung weight.
Implementation Method 1
a locator ring having a fish-mouth tapered lower end has the lower end welded to the arcuate upper surface of the axle
Data Source
AI summary
A clamp group mounting of a leaf spring to a round axle including alignment features is disclosed, which includes a round axle, a leaf spring and a clamp group connecting the leaf spring to a laterally extending axle. A locator ring is welded to an upper arcuate surface of the axle and is received in a recess in a spring seat. The clamp group includes the spring seat, a top pad and a plurality of fasteners that connect the top pad, leaf spring, and spring seat to the axle. The leaf spring extends longitudinally and at least forward or rearward relative to the axle, and includes a bore that receives a locator element that extends at least upward or downward from the leaf spring.