Twist-Axle Cross-Beam With Variable Wall Thickness
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Solution Overview
Problem
Existing twist-axle designs face challenges in meeting both torsional stiffness and load-bearing requirements, often leading to increased manufacturing costs and durability concerns due to stress concentration in transition zones.
Innovation Solution
A cross-beam member with a variable wall thickness along its length, featuring a torsionally elastic central portion and torsionally stiff connection regions, formed from a tubular blank, which allows for smooth transitions in wall thickness to distribute stress evenly and enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a cross-beam member has a mid-section of low torsional stiffness between two transition sections of high torsional stiffness, then the overall torsional stiffness requirement is met, but stress concentration occurs in the transition zones which may cause durability concerns
Solution Approach 1:
The patent applies local quality by varying the wall thickness of the tubular cross-section along the length of the cross-beam member. The wall thickness is increased in the transition zones between the mid-section and end sections, creating locally reinforced areas that reduce stress concentration while maintaining the overall torsional stiffness distribution. This allows different parts of the same component to have different structural properties optimized for their specific functional requirements.
2Stability of the object's composition
If separate parts are used to meet separate design requirements, then torsional stiffness and load bearing requirements can be satisfied, but additional manufacturing and material costs are incurred
Solution Approach 1:
The patent merges the functions of multiple separate components into a single integrated cross-beam member. By incorporating variable wall thickness within one continuous tubular structure, the design achieves both torsional stiffness and load-bearing capabilities without requiring separate torsion bars or multiple assembled parts. This integration eliminates additional manufacturing steps, reduces assembly complexity, and lowers overall material and production costs.
3Reliability
If heat treatment is applied to transition zones to prevent cracking, then durability is improved, but additional manufacturing steps and equipment are required
Solution Approach 1:
The patent addresses durability concerns through local quality enhancement by increasing wall thickness in transition zones rather than applying heat treatment. This structural modification inherently reduces stress concentration and prevents cracking without requiring additional heat treatment processes or specialized equipment. The solution is achieved through the geometric design of the tubular cross-section itself, simplifying the manufacturing process while maintaining reliability.
Data Source
AI summary
The invention relates to a twist-axle that includes a cross-beam member and two trailing arms, each trailing arm rigidly secured to the cross-beam member in one of two connection regions of the cross-beam member or formed integrally with and extending from one of the two connection regions. The cross-beam member is formed from a tubular blank and has a torsionally elastic central portion and two torsionally stiff connection regions. The cross-beam member has a wall thickness that varies longitudinally along the length of the cross-beam member from the torsionally elastic central portion to each of the torsionally stiff connection regions.