Spring Hanger Bolt Assembly with Locking Tab
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Solution Overview
Problem
Conventional methods for connecting trailer axles to frames result in high residual stresses in brackets, leading to potential fractures, and the installation of hanger bolts is dangerous, tiring, and difficult, with bolts being hard to remove for replacement.
Innovation Solution
A spring hanger system with a hanger bolt and axle hanger configuration that includes a locking tab and threaded shank, allowing for secure assembly and disassembly with fewer tools and less effort, reducing stress and installation hazards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If brackets are welded along bend lines to attach to frame, then connection strength is improved, but residual stresses increase leading to bracket fractures
Solution Approach 1:
The bracket attachment is segmented into two distinct zones: bend lines that are not welded to preserve bracket integrity, and edge regions that are welded to provide secure attachment. This segmentation allows the bracket to be firmly attached while avoiding stress concentration at the bend lines.
Solution Approach 2:
Different regions of the bracket are treated differently: the bend line regions maintain a non-welded state to preserve structural integrity and reduce stress, while the edge regions are welded to the frame for secure attachment. This local differentiation optimizes both connection strength and bracket reliability.
2Productivity
If hanger bolts are installed by pounding with sledge hammer, then installation speed is improved, but safety risks and component damage increase
Solution Approach 1:
Holes are pre-drilled through the bracket and align with the leaf spring apertures before bolt installation. This preliminary action eliminates the need for forceful pounding during installation, allowing bolts to be threaded in manually or with minimal tooling, thereby preventing component damage and safety hazards.
Solution Approach 2:
The traditional mechanical pounding method is replaced with a threaded fastening system that uses rotational motion and thread engagement. This substitution eliminates impact forces that cause damage while maintaining secure bolt installation.
3Ease of operation
If hanger bolts are installed by pounding method, then installation ease is improved, but bolt removal difficulty increases
Solution Approach 1:
The irreversible pounding installation method is replaced with a reversible threaded fastening system. Bolts are installed by threading through pre-drilled holes and secured with nuts, allowing easy removal and reinstallation for maintenance and spring replacement.
Solution Approach 2:
The bolt installation system is designed to be recoverable rather than permanent. Nuts and bolts can be easily removed, recovered, and reused for maintenance activities such as spring replacement, improving ease of repair and maintenance.
Data Source
AI summary
An axle hanger includes a web, a first flange extending in a first direction perpendicular to the web, and a second flange extending in the first direction perpendicular to the web, spaced from and parallel to the first flange. A first return extends from the first flange toward the second flange parallel to the web, and a second return extends from the second flange toward the first flange parallel to the web. The axle hanger is easier to install and access in the event a hanger spring needs replacement, and the hanger can be more stably secured to the axle.