One-Piece Connecting Element for Truck Trailer Assembly
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Solution Overview
Problem
Existing connections for trucks, trailers, and semi-trailers require special tools and multiple operations, increasing assembly time and costs, and current security measures like asymmetrical welding are complex and prone to material damage.
Innovation Solution
A one-piece connecting element with a plug-in design that eliminates the need for tools and welding, featuring a non-rotatable connection head and knurling for secure attachment, allowing for quick and easy assembly without damaging the surface finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional screw connections or rivet connections are used, then reliable connection is achieved, but assembly time and assembly costs increase due to special tools and multiple operations
Solution Approach 1:
The connection system is divided into distinct functional elements: a connecting element with connecting head and connecting pin, and a base body with opening. The connecting element can be independently manufactured and then inserted into the base body, separating the manufacturing process from the assembly process and enabling parallel production.
Solution Approach 2:
The connecting element is extracted as a separate, pre-manufactured component that can be independently produced with high precision. This extracted component is then simply inserted into the base body opening, eliminating the need for on-site threading, riveting, or welding operations.
2Reliability
If traditional connections are used, then secure attachment is achieved, but the number of work steps and assembly costs increase
Solution Approach 1:
The connecting element combines multiple functions into a single integrated component: the connecting head provides insertion guidance and positioning, while the connecting pin provides the actual mechanical connection. This merged design eliminates the need for separate positioning features and connection elements.
Solution Approach 2:
The connecting element is pre-manufactured with precise dimensions and features (connecting head geometry, pin dimensions) before assembly. This preliminary action ensures proper fit and function, eliminating the need for on-site adjustments, threading, or additional fastening operations.
3Reliability
If asymmetrical welding is used for customs security, then security against unauthorized access is improved, but the risk of material damage and complexity increase
Solution Approach 1:
The connecting head is designed with an asymmetric cross-sectional shape that does not correspond to any standard fastening element. This asymmetric geometry provides inherent security against unauthorized removal or manipulation, as the connecting element cannot be easily extracted or replaced without damaging the base body opening.
Solution Approach 2:
Instead of using welding to secure the connection (which risks material damage), the design inverts the approach by making the connecting element itself the security feature. The asymmetric connecting head geometry provides the security function that welding would otherwise provide, but without the harmful thermal effects.
Data Source
Figure 1
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AI summary
The connection has a connection element (10). The component is a metallic base body with an opening, and the other component is an attachment with an opening. The connection element is formed in single piece. A connection pin (15) is inserted sectionally in the opening of the base body and is held directly in the opening of the base body.