One-Piece Portal Wheel End Mounting for Stronger Suspension Fitment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The connection between the portal box and the vehicle suspension has not been optimized to improve the strength and fitment of the mounting structure in existing portal wheel end systems for off-road vehicles.
Innovation Solution
A portal gear box assembly with a housing that includes integral mounting brackets on the rear wall, allowing direct connection of the vehicle suspension components, such as A-arms, trailing arms, or swing arms, and steering linkages, eliminating the need for a separate backing plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a separate backing plate is used to mount the portal box to the vehicle suspension, then the mounting structure can be assembled from separate components, but the strength and rigidity of the mounting structure is reduced and flex increases
Solution Approach 1:
The patent combines the portal box housing and mounting bracket into a single integral structure. The mounting bracket is formed as one piece with the housing, eliminating the need for a separate backing plate and multiple fasteners. This merging of components directly increases mounting structure strength and rigidity while reducing the number of parts and assembly complexity.
2Stability of the object's composition
If a separate backing plate is used for mounting, then manufacturing and assembly of individual components is simplified, but the overall fitment and rigidity of the mounting structure deteriorates
Solution Approach 1:
The housing and mounting bracket are manufactured as a single integrated component. This can be achieved through various manufacturing methods such as casting, forging, or stamping the mounting bracket features directly into the housing during the housing manufacturing process. This approach improves structural rigidity and fitment while the integrated manufacturing process maintains ease of production.
3Reliability
If traditional two-piece construction is used, then assembly and disassembly is easier, but the mounting structure exhibits increased flex and reduced secure mounting
Solution Approach 1:
By integrating the mounting bracket into the housing as a single piece, the patent eliminates the interface between separate components that would otherwise allow flex and movement. The integral construction ensures that mounting forces are distributed throughout the housing structure, improving reliability and security of the mounting while reducing the total component count.
Data Source
AI summary
A portal gear box that includes a housing with a rear wall, a upper mounting bracket, a lower mounting bracket extending rearwardly from the rear wall that receive a vehicle suspension component and a side wall extending forwardly from the rear wall, wherein the rear wall defines an opening for an axle, the housing defines an internal recess bounded by the rear wall and the side wall, the rear wall, the side wall, the upper mounting bracket and the lower mounting bracket are unitary, a cover including a front wall that mates with the housing to enclose the internal recess, an output shaft extending through an opening in the front wall, and a linking mechanism in the internal recess that rotationally links the axle to the output shaft.