Segmented Chassis Crossmember Replacement Without Rail Disassembly
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Solution Overview
Problem
Current vehicle chassis crossmembers can fail due to overloading, necessitating labor-intensive replacement processes that require disassembly and reassembly of chassis rails, which is inefficient and prone to downstream issues.
Innovation Solution
The use of adapter plate apparatuses that allow for the introduction and securement of new crossmembers between chassis rail interior planar surfaces and upper/lower flanges without disassembling the rails, utilizing adapter plate components with aligned holes and recesses for efficient coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If crossmembers are made as unitary components mounted between chassis rails, then structural strength is improved, but replacement becomes labor-intensive requiring disassembly of chassis rails
Solution Approach 1:
The crossmember is divided into multiple segments: a first crossmember component mounted to the first chassis rail, a second crossmember component mounted to the second chassis rail, and a planar portion coupling them. This segmentation allows individual components to be replaced independently without disassembling the entire chassis rail structure, resolving the contradiction between maintaining structural strength and enabling easy replacement.
Solution Approach 2:
The planar portion with exterior recesses is nested within the structure of the crossmember components, creating integrated coupling surfaces. This nesting allows the planar portion to serve as both a structural connector and a mounting interface for adapter plates, enabling replacement without chassis rail disassembly while maintaining the unitary structural integrity.
2Loss of time
If adapter plate apparatus is used to couple crossmember components, then replacement time is reduced, but device complexity increases
Solution Approach 1:
The adapter plate apparatus serves multiple functions: it couples the first and second crossmember components together, provides alignment during installation, and enables replacement without chassis rail disassembly. By consolidating these functions into a single standardized component, the system reduces overall complexity while significantly decreasing replacement time.
Solution Approach 2:
The adapter plate apparatus acts as an intermediary component between the first and second crossmember components. This mediator facilitates the coupling operation, allowing rapid assembly and replacement while keeping the overall system design relatively simple through standardized interfaces and alignment features.
3Ease of operation
If crossmember replacement requires disassembly of chassis rails, then access for installation is improved, but productivity decreases due to labor-intensive process
Solution Approach 1:
The planar portion is pre-formed with exterior recesses during manufacturing that are specifically designed to receive adapter plates. This preliminary preparation of the coupling interface eliminates the need for disassembly operations during replacement, allowing direct installation of adapter plates and crossmember components, thereby improving productivity while maintaining ease of operation.
Data Source
AI summary
The disclosed technology relates to vehicle chassis components, including adapter plate apparatuses and vehicle chassis crossmember apparatuses. With this technology, a vehicle chassis crossmember apparatuses can be introduced between chassis rails and secured using an adapter plate apparatus, without requiring disassembly and separation of the vehicle chassis rails. Thus, with this technology, replacement of a failed crossmember can be performed more efficiently, with reduced labor, in a reduced amount of time, and with minimal reassembly of other vehicle components, while maintaining sufficient structural support, among other advantages.