Space Frame Node Design for Off-Highway Load Hauling
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Solution Overview
Problem
Off-highway load hauling machines face challenges with existing frame designs that are heavy and prone to loose bolted joints under torsional loads, leading to safety issues and increased manufacturing costs due to complex fixtures required for curvilinear sockets.
Innovation Solution
A node design for a space frame that includes a core with a projection, a structural member attached to the projection, and top and bottom covers with recesses to securely connect structural members using fasteners, allowing for efficient assembly and improved load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bolted joints are used to connect frame members, then assembly is simplified, but the joints become loose under torsional loads during operation
Solution Approach 1:
The connector is divided into three separable parts that nestle one on top of another on a common axis, allowing modular assembly while maintaining structural integrity through the segmented design
Solution Approach 2:
The three parts of the connector nestle one on top of another on a common axis, with each part containing or receiving the previous part, creating a compact nested structure that maintains strength while enabling assembly
2Adaptability or versatility
If curvilinear sockets with spherical head ends are used, then frame members can be connected in multiple directions, but manufacturing requires complicated fixtures and expensive machining processes
Solution Approach 1:
The connector parts feature asymmetric T-shaped chordal frame member ends with corresponding pairs of matching recesses, eliminating the need for spherical head ends and curvilinear sockets while maintaining multi-directional connection capability
Solution Approach 2:
Instead of using spherical head ends that fit into curvilinear sockets, the design inverts the approach by using T-shaped ends with matching rectangular recesses, simplifying the manufacturing process while achieving the same structural function
3Strength
If heavy gage metal beams and plates are welded together, then the frame can withstand torsional and other stresses, but the frame becomes very heavy
Solution Approach 1:
The space frame uses a composite structure combining tubular members with a triaxial weave carbon fiber wrapped around them, creating a composite material system that provides high strength-to-weight ratio to withstand torsional and other stresses while reducing overall frame weight
4Weight of moving object
If space frame with triangulated structural members is used, then machine weight is reduced, but joining requires specialized tooling and fixtures increasing manufacturing cost and time
Solution Approach 1:
The connector design features mating pairs of interior surfaces with T-shaped ends and corresponding recesses that can accommodate multiple frame member orientations and configurations, allowing a single connector type to serve multiple joining functions without requiring specialized tooling or fixtures for each configuration
Data Source
AI summary
A node is disclosed. The node may have a core. The node may also have a projection extending from the core. Further the node may have a structural member attached to the projection. The node may also have a top cover having a top recess. The top recess may be configured to receive the structural member. Additionally, the node may have a bottom cover having a bottom recess. The bottom recess may be configured to receive the structural member. In addition the node may have a fastener to connect the top cover and the bottom cover.