Lightweight Trailer Overrun Brake Housing With Steel Locking Stop
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing overrun brake systems for trailers are heavy due to their robust steel construction, reducing payload capacity and posing safety risks due to potential failure and separation from the towing vehicle.
Innovation Solution
An overrun device with a lightweight drawbar and locking element made of light metal, plastic, or composite materials, secured by a steel locking element that stabilizes the connection between the trailer and towing vehicle, preventing separation and allowing use of non-steel bearing housings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the overrun device is constructed with robust steel materials to ensure strength and reliability, then the connection strength and safety are improved, but the weight of the overrun device increases significantly
Solution Approach 1:
The overrun device is divided into two functional segments: a lightweight bearing housing (made of aluminum, plastic, or composite materials) and a steel locking element. This segmentation allows each component to be optimized for its specific function - the bearing housing for lightweight operation and the locking element for secure connection - thereby resolving the contradiction between weight reduction and strength maintenance.
Solution Approach 2:
Steel material is applied locally only where absolutely necessary for safety (the locking element that prevents separation), while the bearing housing uses lightweight materials. This localized application of high-strength material resolves the contradiction by concentrating strength where needed without unnecessarily increasing overall weight.
2Weight of moving object
If the bearing housing is made from lightweight materials (light metal, plastic, or composite) to reduce weight, then the payload capacity is improved, but the strength and load-bearing capacity of the bearing housing deteriorates
Solution Approach 1:
The device segments the load-bearing functions: the lightweight bearing housing handles rotational support and movement guidance, while the steel locking element handles the critical load-bearing and connection security functions. This allows the housing to be lightweight without sacrificing overall structural strength.
Solution Approach 2:
The system effectively creates a composite structure combining lightweight materials (aluminum, plastic, or composite housing) with steel (locking element). This composite approach allows the bearing housing to be lightweight while the steel locking element provides the necessary load-bearing capacity and strength.
3Device complexity
If the locking element is integrated into the bearing housing to simplify structure, then the device complexity is reduced, but the ability to provide additional stabilization and prevent separation deteriorates
Solution Approach 1:
The locking element is designed as a separate, independently attachable component rather than being integrated into the bearing housing. This segmentation allows the locking element to provide dedicated stabilization and separation prevention functions while maintaining relatively simple overall device structure through modular assembly.
Data Source
Figure 1~2
Figure 3A~3B
Figure 4
AI summary
The invention relates to an overrun device 100 for a trailer 10, wherein the overrun device 100 comprises a drawbar 106, at least one locking element 130, and a bearing housing 120. The bearing housing is a light metal housing, a plastic housing, or a composite material housing. The drawbar is mounted in the bearing housing 120 so as to be translationally displaceable and is configured to actuate a brake 16 of the trailer 10 when the drawbar 106 is displaced relative to the bearing housing 120 in the opposite direction of travel. The locking element 130 is distinct from the bearing housing 120 and is configured to be rigidly connected to the trailer, the locking element 130 having a stop 134 which limits the movement of the drawbar 106 relative to the bearing housing 120 in the forward direction of travel.