Modular Commercial Vehicle Chassis Weight Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Commercial vehicle chassis designs face challenges with high dead weight due to additional components and stricter emission regulations, leading to reduced payload, increased fuel consumption, and higher costs, while existing modular designs for independent wheel suspensions often result in added weight and complexity.
Innovation Solution
A modular chassis design featuring a front subassembly, rear subassembly, and middle subassembly with independent wheel suspension modules, utilizing upper and lower chords connected by shear-resistant connectors to reduce weight and simplify structure, allowing for flexible attachment and optimal force distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a continuous ladder frame is used for commercial vehicle chassis, then structural strength and rigidity are maintained, but dead weight increases significantly
Solution Approach 1:
The chassis is divided into modular assemblies (front subassembly, rear subassembly, middle subassembly) that can be independently designed and optimized. Each assembly contains specific components (axles, suspension, exhaust systems) that can be selectively configured, allowing weight reduction while maintaining overall structural integrity through the modular architecture.
2Object-affected harmful factors
If additional exhaust gas treatment components are added to meet emission regulations, then emission compliance is improved, but vehicle dead weight increases
Solution Approach 1:
Exhaust gas treatment components (catalytic converters, urea tanks, exhaust systems) are integrated within the hollow profile structures of the middle subassembly. The internal cavity of the box structure accommodates these components, allowing them to be nested within the existing structural framework rather than adding separate external components, thereby reducing overall weight while maintaining emission compliance.
3Reliability
If heavy and complex consoles are used to connect independent wheel suspension to the frame, then vibration and rigidity problems are avoided, but chassis weight increases and assembly complexity increases
Solution Approach 1:
The connection structures for independent wheel suspension are merged with the longitudinal beams and cross members of the modular chassis assemblies. The front and rear subassemblies incorporate mounting points and structural elements that directly integrate suspension components into the existing frame structure, eliminating the need for separate heavy consoles while maintaining rigidity and vibration resistance.
4Ease of manufacture
If a modular design with detachable connection points is implemented, then assembly flexibility and ease of assembly are improved, but structural rigidity may be compromised
Solution Approach 1:
The modular assemblies are pre-configured with integrated connection points and structural elements during manufacturing. The detachable connections are designed with pre-positioned mounting features that ensure proper alignment and rigid connection when assembled, eliminating the need for complex field adjustments while maintaining structural integrity. The preliminary integration of suspension mounting points ensures rigidity is preserved even with detachable connections.
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A chassis for commercial vehicles, in particular for semi-trailer tractors, is described, comprising: a front assembly (10) assigned to a front axle area of the commercial vehicle, a rear assembly (14) assigned to a rear axle area of the commercial vehicle, and a middle assembly (12) which connects the front assembly (10) and the rear assembly (14).