Trailer Floor Assembly with Variable-Height Beams and Truss Members
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Solution Overview
Problem
Existing trailer chassis and floor designs face challenges in increasing load capacity while minimizing weight and size to meet stricter emissions and fuel efficiency requirements, as larger and heavier structures often fail to comply with these standards.
Innovation Solution
The design incorporates a pair of main beams with varying heights, transverse cross members, and extruded reinforced floor members with truss walls extending at an angle, which are positioned on the main beams' upper surfaces and joined using friction stir welding to form a lightweight yet robust floor assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the sizes of structural members (main beams, cross members, floor members) are increased to increase load capacity, then load capacity is improved, but weight and size increase
Solution Approach 1:
The patent employs composite structural members combining aluminum alloy main beams with steel cross members and floor members. This composite approach allows each material to be used where it provides optimal strength-to-weight ratio, achieving high load capacity while minimizing overall weight compared to using a single heavy material throughout
Solution Approach 2:
The main beams feature variable cross-sections with different height dimensions at different locations along their length. The beams have greater height at mid-span sections where bending moments are highest, and reduced height at end sections where loads are lower. This local optimization provides necessary strength where required while reducing weight in less critical areas
2Strength
If the sizes of structural members are increased to increase load capacity, then load capacity is improved, but size increases
Solution Approach 1:
The main beams are designed with non-uniform cross-sections where the height varies along the longitudinal direction. Sections with higher load requirements have greater height dimensions, while sections with lower requirements have reduced height, optimizing the volume of material used to match the actual load distribution pattern
Solution Approach 2:
By using aluminum alloy for main beams (which have large volume requirements) and steel for cross members and floor members (which require less volume but high local strength), the patent achieves high load capacity with minimized overall volume of the chassis structure
3Strength
If larger and heavier trailers are used to increase load capacity, then load capacity is improved, but fuel efficiency deteriorates
Solution Approach 1:
The mixed aluminum-steel construction reduces the overall weight of the chassis structure compared to all-steel designs, directly decreasing the mass that the propulsion system must move and thereby improving fuel efficiency while maintaining required load capacity
Solution Approach 2:
The variable cross-section main beams reduce material volume and weight in regions where full strength is not required, decreasing the overall chassis weight and improving fuel efficiency without compromising the load-bearing capability where it is most needed
4Strength
If larger and heavier trailers are used to increase load capacity, then load capacity is improved, but emissions deteriorate
Solution Approach 1:
By reducing chassis weight through composite aluminum-steel construction, the patent decreases the fuel consumption required to operate the trailer, which directly reduces greenhouse gas emissions and other exhaust pollutants from the prime mover
Solution Approach 2:
The optimized variable cross-section beams minimize material usage while maintaining structural integrity, reducing overall chassis weight and consequently lowering the emissions generated during trailer operation
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
This configuration enhances load capacity with reduced mass, maintaining structural integrity and compliance with emissions and fuel efficiency standards by distributing weight efficiently and providing a strong, lightweight trailer floor.
Implementation Method 1
The floor members can be stir welded to adjacent floor members.
Data Source
AI summary
A floor assembly for a trailer includes a pair of longitudinally extending main beams, each having a first height dimension along a first longitudinal portion of the main beam and a second height dimension along a second portion of the main beam. The first height dimension being greater than the second height dimension. Cross members extend in a transverse direction between and connect the main beams. A plurality of floor members extend transversely between the main beams. The floor members including at least some reinforced floor members. The reinforced floor members have upper and lower walls and opposing side walls that define a rectangular cross-section and include a series of truss walls extending angularly between the upper and lower walls. The reinforced floor members are positioned on the upper surfaces of the main beams at least in part at the second height dimension.