Monolithic Crossbar Connection for Void-Free Implement Coupling
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Solution Overview
Problem
Current crossbar constructions for heavy equipment implements face challenges in maintaining parallel surfaces, leading to reduced planar surface length, localized stress points, and increased susceptibility to failure due to voids and material separations in the connection zone.
Innovation Solution
The development of a crossbar with a uniform, void-free, and interface-free construction using extruded or cast materials, ensuring consistently parallel connection surfaces across the hookup location, which enhances strength and resistance to torque, and reduces manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If attachment plates are welded to pipe sections to create crossbar connection zones, then the crossbar can be assembled from standard pipe components, but the welding process creates voids and interfaces that become stress concentration points leading to failure
Solution Approach 1:
The patent merges the attachment plates and pipe sections into a single monolithic crossbar component. Instead of assembling separate parts with welds, the entire crossbar is manufactured as one piece using extrusion or casting processes, eliminating the welds and interfaces that create stress concentration points and voids.
Solution Approach 2:
The patent transitions from composite construction (multiple materials joined by welding) to a homogeneous monolithic structure. The crossbar is made from a single material throughout, eliminating the interfaces between different materials (pipe, attachment plates, weld material) that create reliability issues.
2Ease of manufacture
If attachment plates are spaced from the center line to allow welding access, then the connection zone can be manufactured, but the planar surface length is reduced making parallel surface maintenance extremely difficult
Solution Approach 1:
The patent combines the attachment plates and pipe into a monolithic structure where the connection surfaces are integrally formed. This eliminates the need to maintain parallelism between separate components, as the surfaces are created as a single unit during extrusion or casting, naturally ensuring parallelism without complex machining or grinding operations.
3Adaptability or versatility
If multiple materials and interfaces are used in the connection zone for flexibility, then the crossbar can accommodate different manufacturing processes, but the number of separation locations increases creating more potential failure points
Solution Approach 1:
The patent merges multiple components into a single monolithic crossbar that can still be manufactured using various processes (extrusion, casting, machining). This maintains manufacturing flexibility while eliminating the interfaces between different materials that create failure points. The monolithic design allows the same component to be produced through different methods without requiring assembly of multiple parts.
Data Source
AI summary
A method of constructing an improved attachment or implement for use with equipment connected to a coupler is provided. The implement has a crossbar which is one of machined, cast or extruded to provide a cross section within at least the connection zone which lacks welds while still providing parallel flats for connecting to a channel in the coupler. The cross section in the connection zone is void-free and seam free.