Space Frame Center Lower Connection Casting

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Solution Overview

Problem

Conventional space frame structures for haul trucks face challenges in dynamic applications due to loads, bending, and flexing, requiring carefully designed high-strength castings and fabrications to ensure proper load transfer and stiffness while maintaining flexibility, which is difficult to achieve with traditional nodal connections.

Innovation Solution

The design of a center lower frame connection casting for space frames, featuring an outer lift cylinder connection boss, inner drop tube connection boss, center cylinder, suspension connection boss, and angular beams, which are integrally attached and oriented at acute angles to provide a lightweight and durable structure for off-highway rear haul trucks, ensuring effective load transfer and flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional welded steel frames are used, then strength and load-bearing capacity are achieved, but weight increases significantly and manufacturing complexity increases due to extensive welding requirements

Engineering Contradiction:

Improveload-bearing capacityVSAvoidframe weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent combines multiple frame members and connection nodes into a single integrated space frame structure. The nodal connections serve as merging points where multiple tubular members converge, creating a unified load-bearing structure that eliminates the need for separate welding operations while maintaining structural integrity and reducing overall weight compared to conventional welded steel frames

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The space frame employs a composite construction approach using multiple tubular members with different orientations and connection types. The structure integrates various geometric shapes and material configurations within the nodal connections to achieve optimal strength-to-weight ratio, combining the advantages of different structural forms while minimizing material usage

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If conventional space frame structures are used, then weight is reduced, but reliability and load transfer capability deteriorate under dynamic vehicular loads and terrain conditions

Engineering Contradiction:

Improveframe weightVSAvoidload transfer capability

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The nodal connections are designed with dynamic characteristics that allow them to respond to varying load conditions. The connection geometry and material properties enable the structure to flex and adapt under dynamic vehicular loads, terrain-induced stresses, and bending forces, maintaining reliability while preserving the weight advantages of space frame construction

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent applies different connection configurations and geometric properties at specific locations within the space frame. Each nodal connection is optimized for its particular position and load requirements, with varying tube diameters, wall thicknesses, and connection angles to ensure optimal load transfer capability while maintaining overall structural lightness

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If fabricated nodal connections are used, then manufacturing simplicity is achieved, but manufacturing precision and stiffness characteristics become difficult to control under dynamic conditions

Engineering Contradiction:

Improveconnection fabricationVSAvoidstiffness control

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The nodal connections are designed with pre-determined geometric properties and connection angles that are established during the manufacturing process. The tube orientations, connection node geometries, and structural configurations are predetermined to achieve the desired stiffness characteristics and load transfer properties, ensuring manufacturing precision is built into the design from the outset

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent utilizes variations in geometric parameters such as tube diameter, wall thickness, connection angles, and node geometry to control stiffness characteristics. By carefully selecting and adjusting these parameters during the design and manufacturing process, the structure achieves the required stiffness and flexibility characteristics while maintaining ease of manufacture through standardized connection configurations

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11292530B2Space frame center lower frame connection

Publication Date: 2022.04.05 CATERPILLAR INC

AI summary

A center lower frame connection for a space frame comprising an outer lift cylinder connection boss, an inner drop tube connection boss, a center cylinder between the outer lift cylinder connection boss and the inner drop tube connection boss, a suspension connection boss, an outer rearward angular center lower frame tube connection boss, an inner rearward angular center lower frame tube connection boss, a vertical center lower frame tube connection boss, a forward angular center lower frame tube connection boss, an outer forward horizontal center lower frame tube connection boss, and an inner forward horizontal center lower frame tube connection boss. The outer lift cylinder connection boss, the inner drop tube connection boss, and the center cylinder can have a common center axis. The center lower frame connection can also have a rearward angular beam and a forward horizontal beam.