Twist Beam Axle Lateral Adjustment Mounting Bracket
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Solution Overview
Problem
Manufacturing variations in twist beam and trailing arm components lead to unsatisfactory welded joints in twist beam axle assemblies, resulting in fatigue and cracking, due to the need for multiple direct welds between these components.
Innovation Solution
A twist beam axle assembly design featuring a pair of trailing arms and a twist beam with side walls that allow for axial and vertical adjustment through mounting brackets, reducing the number of direct welds and enhancing manufacturing flexibility by absorbing variations in component sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple direct welds are used to secure the twist beam to the trailing arms, then the structural strength is improved, but the risk of fatigue and cracking increases due to manufacturing variations
Solution Approach 1:
The patent introduces mounting brackets as intermediary components between the twist beam and trailing arms. These brackets provide adjustment mechanisms that accommodate manufacturing variations, allowing for precise alignment and positioning. This intermediary structure reduces stress concentrations and minimizes the risk of fatigue and cracking in the welded joints, while still maintaining structural strength through properly positioned connections.
2Device complexity
If the twist beam is directly welded to the trailing arms, then the device complexity is reduced, but the manufacturing precision deteriorates due to inability to accommodate variations
Solution Approach 1:
The mounting brackets incorporate adjustment mechanisms that allow for dynamic positioning and alignment during assembly. This enables the system to accommodate manufacturing variations in both the twist beam and trailing arms, achieving precise alignment without requiring extremely tight manufacturing tolerances on the base components themselves.
Solution Approach 2:
The mounting brackets serve as intermediary components that provide adjustment capabilities. These brackets include features such as adjustable length members or positioning mechanisms that allow fine-tuning of the connection between the twist beam and trailing arms, thereby achieving high assembly precision even when component dimensions vary within manufacturing tolerances.
3Adaptability or versatility
If adjustment mechanisms are added to accommodate manufacturing variations, then the manufacturing flexibility is improved, but the device complexity increases
Solution Approach 1:
The mounting bracket assembly is segmented into distinct functional components, including adjustment mechanisms, connection interfaces, and securing elements. This segmentation allows each component to perform its specific function independently, making the adjustment process more manageable and the overall system easier to assemble despite the added flexibility capabilities.
Solution Approach 2:
The mounting brackets are designed as self-contained intermediary units that incorporate all necessary adjustment mechanisms within them. This consolidates the complexity into discrete, manageable modules rather than distributing adjustment requirements throughout the entire assembly, thereby improving manufacturing flexibility while keeping the overall device complexity controlled through modular design.
Data Source
AI summary
A twist axle assembly (20) of a vehicle includes a pair of trailing arms (22) and a twist beam (24) having a base portion (46) extending along an axis (A) between first and second twist beam ends (42, 44). The twist beam (24) includes a pair of side walls (48) extending downwardly from the base portion (46) and each disposed in spaced relationship with the trailing arms (22). At least one mounting bracket (54) extends from a first mounting bracket end (56) disposed in abutting relationship with a respective trailing arm (22) to a second mounting bracket end (58) disposed in overlaying relationship the side walls (48) of the twist beam (24) for allowing the mounting bracket to axially slip or slide along the side walls (48) of the twist beam (24) and provide for lateral or axial adjustment of the twist axle assembly (20) during the manufacturing process.