Modular Air Spring Carrier Design for Commercial Vehicle Axles
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Solution Overview
Problem
Conventional air spring supports for commercial vehicles are costly to manufacture and have variable load-bearing capacity due to weld seam quality issues, requiring complex tools and high manufacturing effort.
Innovation Solution
A modular air spring carrier design featuring a central part and fixed arms, allowing for optimal design and manufacturing of each component to handle different loads, using semi-finished products and cost-effective adaptation to various vehicle models, with secure fastening devices and stress distribution through tapered areas and friction welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional air spring supports are manufactured using welded half-shells, then the structural integrity is improved, but the manufacturing cost and complexity increase due to variable weld seam quality and additional brackets
Solution Approach 1:
The air spring carrier is divided into a center part and two arms that can be manufactured separately and then assembled. This segmentation allows each component to be optimized independently, reducing manufacturing complexity while maintaining structural integrity through the fixed connection between parts.
Solution Approach 2:
The center part and arms are fixedly attached to form an integrated structure that combines the advantages of separate manufacturing with the strength of a unified component. This merging eliminates the need for complex welding of half-shells while preserving load-bearing capacity.
2Reliability
If welded brackets are added to compensate for variable weld seam quality, then the reliability is improved, but the manufacturing cost and time increase
Solution Approach 1:
By segmenting the carrier into separately manufacturable center part and arms, the invention eliminates the need for additional welded brackets. Each segment can be manufactured with consistent quality controls, and the fixed connection ensures reliable assembly without requiring time-consuming welding operations.
3Manufacturing precision
If complex tools are used for manufacturing half-shells, then the manufacturing precision is improved, but the manufacturing cost and effort increase
Solution Approach 1:
The carrier is segmented into simpler components (center part and arms) that can be manufactured using less complex tools and processes. This segmentation maintains manufacturing precision for critical features while significantly reducing the overall manufacturing effort and tooling requirements compared to forming complex welded half-shells.
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
The modular design reduces manufacturing complexity and costs, enhances load-bearing stability, and adapts to different vehicle models, ensuring reliable and cost-effective production while minimizing strength scatter and weight.
Implementation Method 1
The middle part has a first fastening device for the axle-side connection of the air spring carrier and a second fastening device for connection of a trailing arm. Each of the arms has a third fastener for mounting an air spring.
Data Source
Figure 1A~1B
Figure 2~3
Figure 4~5
AI summary
The invention relates to an air spring support (1) for an air-sprung axle of a commercial vehicle. The air spring support (1) comprises a central part (10) having a first fastening device (14, 15, 17) for connecting the air spring support (1) to the axle and a second fastening device (11, 12, 13) for connecting a trailing arm; and two arms (30) which are fixedly attached to the central part (10) on opposite sides and each have a third fastening device (34) for holding an air spring.