Twist Beam Axle Assembly with Open Section Torsion Bar
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Solution Overview
Problem
Existing axle assemblies face challenges in quickly and inexpensively adjusting, tuning, and scaling their design to achieve desired torsional stiffness and shear center position due to complex shapes and dedicated tooling requirements.
Innovation Solution
The axle assembly design includes a twist beam with an open section, outriggers, and a torsion bar, where the twist beam's physical parameters and the torsion bar's attachment points are optimized to achieve predetermined torsional stiffness and shear center position, allowing for variations in beam openings, scallops, and roll-formed configurations to meet specific requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dedicated tooling is used to produce complex shapes of structural elements, then manufacturing precision and structural performance are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The structural element is divided into multiple extrusion segments that can be produced separately using simpler tooling, then assembled together. This segmentation allows each segment to be manufactured with less complex tooling while maintaining overall structural precision through the assembly process.
Solution Approach 2:
The design employs universal extrusion tooling that can produce multiple different structural elements through parameter adjustments rather than requiring dedicated tooling for each unique shape. This multi-functional approach reduces tooling complexity while maintaining manufacturing precision across various structural configurations.
2Manufacturing precision
If dedicated tooling is used for unique axle assembly designs, then manufacturing precision is improved, but productivity and scalability deteriorate
Solution Approach 1:
The system incorporates adjustable and reconfigurable tooling parameters that can be dynamically modified to produce different axle assembly designs. This dynamic capability allows rapid design adjustments and tuning without requiring new dedicated tooling, thereby improving productivity and scalability while maintaining manufacturing precision.
Solution Approach 2:
The invention utilizes parameter-based design where structural characteristics are controlled by adjustable parameters in the extrusion process. By changing these parameters, different axle assembly designs can be produced with the same base tooling, enabling rapid design iteration and scaling without sacrificing manufacturing precision.
3Strength
If complex shapes are produced with dedicated tooling, then structural performance is improved, but ease of manufacture deteriorates
Solution Approach 1:
Complex structural elements are segmented into simpler components that can be manufactured using easier, less specialized processes. The segmentation maintains structural integrity and strength through proper design of connection interfaces between segments, thereby improving ease of manufacture without compromising structural performance.
Solution Approach 2:
Multiple simpler structural components are merged or assembled to create the final complex structure. This merging approach allows each component to be manufactured with simpler tooling and processes, improving ease of manufacture while achieving the required structural performance through the combined assembly.
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 approach enables the production of axle assemblies with tailored torsional stiffness and shear center position, facilitating cost-effective and rapid adjustments to ride, handling, and durability specifications, reducing the need for expensive retooling and simplifying the manufacturing process.
Implementation Method 1
The torsion bar extends through and is connected to the first outrigger at a first bar attachment point and the second outrigger at a second bar attachment point. The torsion bar extends transversely within the open portion of the twist beam. A predetermined torsional stiffness and a predetermined position of a shear center of the axle assembly can be obtained based on the location of the first bar attachment point and the second bar attachment point relative to the twist beam.
Data Source
AI summary
An axle assembly includes a first rail assembly, a second rail assembly and an open-section twist beam connected to the first rail assembly and the second rail assembly. The twist beam includes an upper wall, a lower wall and rear wall wherein the upper wall and the lower wall are connected by the rear wall to define an open portion of the twist beam where the upper wall and the lower wall are separated by a vertical distance. The open portion of the twist beam is forward facing. The axle assembly further includes a torsion bar that extends through and is connected within the open portion of the twist beam.