Torsion Beam Axle Collar Joint for Reinforcement Plate Corrosion Resistance
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Solution Overview
Problem
Existing torsion beam axles face challenges in the connection of reinforcing plates to the torsion tube, particularly in terms of manufacturing complexity, cost, and corrosion resistance at the joining area.
Innovation Solution
A torsion beam axle design featuring a semi-open profile torsion tube with reinforcing plates inserted and coupled through a collar passage system, utilizing a combination of positive and non-positive fits, which allows for precise, cost-effective, and corrosion-resistant assembly, effectively absorbing shear forces and maintaining structural integrity under operational stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If reinforcing plates are bolted to the torsion tube, then the connection is simple and cost-effective, but the corrosion resistance at the joining area is insufficient
Solution Approach 1:
The invention merges the reinforcing plate with the torsion tube by inserting the plate into the hollow profile and bonding it to the inner surface, creating an integrated connection that eliminates separate fastening elements and exposes only a single-layer surface for corrosion protection coating
Solution Approach 2:
The invention uses an intermediary bonding process (adhesive bonding or friction stir welding) to connect the reinforcing plate to the torsion tube inner surface, providing both structural connection and a uniform surface that can be properly coated for corrosion protection
2Strength
If reinforcing plates are welded to the torsion tube, then the connection strength is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The invention replaces traditional mechanical welding processes with alternative bonding methods such as adhesive bonding or friction stir welding, which achieve comparable or superior connection strength while reducing manufacturing complexity and cost
Solution Approach 2:
The invention changes the bonding parameters by using surface bonding to the inner profile wall with controlled bond lines, allowing for optimized connection strength without the complexity of traditional welding procedures
3Ease of manufacture
If clinching or embossing is used to connect the reinforcing plate, then the manufacturing is simple, but the corrosion protection is compromised due to double-layered material
Solution Approach 1:
The invention extracts the problematic double-layered material structure created by clinching or embossing and replaces it with a single-layer surface bonding approach, where the reinforcing plate bonds to the inner surface without creating overlapping material layers that trap moisture and prevent proper corrosion protection coating
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 simplifies the manufacturing process, enhances corrosion resistance, and ensures the torsion beam axle can withstand operational stresses, including alternating bending and vibrations, while maintaining a stress-free assembly state.
Implementation Method 1
The reinforcing plate is coupled to the torsion tube, in particular at least partially by a material-bonded joining process, especially a welding process
Data Source
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AI summary
The present invention relates to a compound link axle for a motor vehicle, comprising a torsion tube (2) and longitudinal swing arms coupled at the ends of the torsion tube, wherein the torsion tube (2) is designed in its cross-section at least partially as a semi-open profile and a reinforcing plate (8) is inserted and coupled in the torsion tube, wherein the reinforcing plate (8) is positively coupled to the torsion tube (2) via a collar opening (14).