Modular Axle Clamp Riser System With Interchangeable Components

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Solution Overview

Problem

Existing clamping systems for heavy vehicle suspensions face challenges in accommodating various axle designs, requiring unique tooling and machining for minor variations, leading to high costs and inefficiencies due to the need for specialized production and inventory management.

Innovation Solution

A modular axle clamp and riser system with interchangeable components and a smart part numbering system, allowing for easy assembly and reduced machining, featuring chamfered edges for robotic welding and adjustable pinion angles, along with a unique part numbering system for efficient production and ordering.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional clamping systems are designed to accommodate various axle designs, then all suspension configurations can be served, but the number of different clamping systems increases to thousands requiring special assembly and manufacturing

Engineering Contradiction:

Improvecompatibility with various axle designsVSAvoidnumber of different clamping systems

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The clamping system is divided into multiple interchangeable components including clamp bodies, spacers, and mounting brackets that can be independently selected and combined. Each component has standardized interfaces allowing them to work together in various configurations, reducing the need for completely different clamping systems for each axle design variation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The clamp body is designed with universal features including multiple hole patterns and adjustable mounting options that allow a single clamp body design to accommodate different axle types and configurations. The spacer components provide adjustable positioning capabilities, enabling the same basic clamping system to serve multiple suspension configurations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If minor variations in axle design are accommodated by creating specialized clamping systems, then performance requirements are met, but production tooling and machining costs increase significantly

Engineering Contradiction:

Improveperformance and handling requirementsVSAvoidproduction tooling and machining costs

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Instead of creating entirely different clamping systems for minor axle variations, the invention modifies only specific local features of existing components. For example, spacers can be adjusted in thickness or positioning, and mounting brackets can have minor dimensional variations, while the main clamp body remains unchanged. This approach maintains performance requirements while avoiding the need for complete redesign and new tooling.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If low quantity orders for specific clamping system configurations are produced with specialized tooling, then customer needs are met, but the process is not cost effective

Engineering Contradiction:

Improvecustomization for specific customersVSAvoidcost effectiveness for low quantity orders

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The clamping system incorporates adjustable and reconfigurable features that allow rapid adaptation to different customer specifications without requiring dedicated tooling for each order. Components such as spacers and mounting brackets can be easily repositioned or replaced to accommodate different ride heights and configurations, enabling cost-effective production of low-quantity custom orders using the same basic manufacturing setup.

Inventive Principle:

Principle #15Dynamics

4Ease of operation

If spacers are included to increase ride height, then customer preference for higher ride height is satisfied, but the number of design parameters increases requiring more variations in clamping systems

Engineering Contradiction:

Improveride height adjustmentVSAvoidnumber of design parameters

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The clamping system is designed with pre-configured spacer components and adjustable mounting positions that allow ride height adjustment to be achieved through simple component selection rather than complex design variations. Standardized spacer thicknesses and pre-drilled hole patterns enable ride height customization without increasing the overall complexity of the clamping system design.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250353341A1Modular axle clamp and riser system

Publication Date: 2025.11.20 HENDRICKSON MT VERNON LLC

AI summary

A modular axle clamp and riser system for use in a suspension system, which includes a top mount having a substantially flat upper surface, a top mount body which extends transversely to the flat upper surface, a pair of opposing ears which extend from the top mount body, and at least one top mount tooth extending from the top mount body in a direction opposite the ears. Also included is a wedge with at least one wedge tooth which matingly engages the at least one top mount tooth, a wedge upper surface, and a pinion angle surface. Further, the wedge defines a pinion angle between the wedge upper surface and the pinion angle surface. Moreover, an axle mount with at least one axle mount tooth which matingly engages at least one of the at least one top mount tooth and the at least one wedge tooth is provided.