Spring Beam Suspension With Pivot Bracket And Lift Actuator
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Solution Overview
Problem
Conventional spring beam suspension systems are complex, expensive to manufacture and maintain, and do not securely retain the pivot bushing, making them unsuitable for applications requiring axle lift and prone to instability.
Innovation Solution
A spring beam suspension system with a solid one-piece hanger, a flexible spring beam, and a U-shaped pivot bracket securely attached to the hanger, along with a lift actuator that applies a downward biasing force to lift the axle, allowing the beam to pivot relative to the bushing and reducing manufacturing and maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional spring beam suspension system is used, then the axle can be suspended, but the system is complex and expensive to manufacture and maintain
Solution Approach 1:
The hanger is divided into a main body portion and a bracket portion that are separable, allowing the bracket to be removed and replaced without replacing the entire hanger assembly. This reduces manufacturing costs and simplifies maintenance while maintaining system functionality.
Solution Approach 2:
The bracket is extracted as a separate, removable component from the hanger assembly. This allows the bracket to be independently manufactured, inspected, and replaced, reducing overall system complexity and manufacturing expenses while preserving the suspension function.
2Reliability
If a conventional spring beam suspension system is used, then the spring beam can flex, but the pivot bushing is not securely retained
Solution Approach 1:
The bracket is designed to wrap around and enclose the forward end of the spring beam, merging the retention function into the bracket structure itself. This secure enclosure retains the pivot bushing and spring beam without requiring additional complex retention mechanisms.
Solution Approach 2:
Instead of securing the bushing to the spring beam directly, the bracket secures the spring beam to the hanger, indirectly securing the bushing. This inverted approach provides more reliable retention while simplifying the overall structure.
3Ease of operation
If a conventional spring beam suspension system is used, then the system can operate, but it is difficult to lift the axle
Solution Approach 1:
A lift actuator is introduced as an intermediary component between the power source and the spring beam. This actuator applies downward force on the forward end of the spring beam, which translates to upward lift on the axle, providing easy operation without complex direct lift mechanisms.
Solution Approach 2:
The lift mechanism operates by applying force in the vertical dimension at the forward end of the spring beam, which creates a rotational moment that lifts the axle in the opposite direction. This dimensional approach simplifies the lift mechanism while maintaining effectiveness.
4Ease of manufacture
If a conventional spring beam suspension system is used, then the spring beam can absorb torsional loads, but the hanger is expensive to manufacture and maintain
Solution Approach 1:
The hanger is segmented into a main body and a separate bracket, allowing the main body to be optimized for torsional strength while the bracket is optimized for retention and connection functions. This segmentation reduces manufacturing costs while preserving torsional load absorption capability.
Solution Approach 2:
Different portions of the hanger are designed with different properties: the main body is designed for strength and torsional resistance, while the bracket is designed for ease of manufacture and replacement. This local differentiation reduces overall manufacturing costs while maintaining required strength.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a lighter, less complex, and more reliable suspension system with reduced manufacturing and maintenance costs, capable of securely lifting the axle and improving lateral stability, while allowing for easier assembly and weight savings.
Implementation Method 1
a flexible spring beam extending between the hanger and an axle
Implementation Method 2
causing the spring beam to torsionally flex. Some of this torsional loading is absorbed by a pivot bushing
Implementation Method 3
a lift actuator which lifts the axle by applying a biasing force to a portion of the spring beam
Data Source
AI summary
A spring beam suspension system includes a hanger; a flexible spring beam extending between the hanger and an axle; and a generally U-shaped pivot bracket secured to the spring beam, the pivot bracket including opposing legs which are pivotably attached to the hanger. Another spring beam suspension system includes a lift actuator which lifts the axle by applying a biasing force to a portion of the spring beam which extends forward from the hanger. Yet another suspension system has a bushing secured in the hanger, whereby the beam pivots relative to the bushing.