Twist Beam Axle Weld-Less Joint Bushing Design
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Solution Overview
Problem
Manufacturing variations in twist beam and trailing arm components lead to challenges in fitting and result in unsatisfactory welded joints in twist beam axle assemblies, causing fatigue and cracking.
Innovation Solution
A twist beam axle assembly with bushings establishing weld-less joints between the twist beam and trailing arms, allowing for a robust and fatigue-resistant connection without welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to secure the twist beam to the trailing arms, then a strong joint is achieved, but manufacturing variations lead to fatigue and cracking
Solution Approach 1:
The patent introduces bushings as intermediary components between the twist beam and trailing arms. These bushings serve as mediators that accommodate manufacturing variations and provide a reliable connection without direct welding, thereby maintaining joint strength while improving reliability by eliminating welding-induced stress concentrations and cracks.
Solution Approach 2:
The patent replaces the welding process with a mechanical bushing-based connection system. Instead of using thermal welding to join the twist beam and trailing arms, the invention uses mechanically fitted bushings that provide equivalent or superior joint performance while avoiding the harmful effects of welding such as heat-affected zones, residual stresses, and susceptibility to cracking.
2Device complexity
If direct welding is used between twist beam and trailing arms, then assembly is simplified, but manufacturing variations cause fitting challenges and unsatisfactory joints
Solution Approach 1:
The bushings act as intermediary components that bridge the gap between the twist beam and trailing arms, accommodating manufacturing variations in dimensions and tolerances. This intermediary approach maintains assembly simplicity while resolving fitting challenges caused by manufacturing variations, as the bushings can be manufactured to precise tolerances and provide a standardized interface.
3Stability of the object's composition
If welding is used to secure components, then a rigid connection is achieved, but the welded joint becomes susceptible to fatigue and cracking
Solution Approach 1:
The patent substitutes the welding process with a mechanical bushing connection system that provides adequate rigidity while eliminating the inherent weaknesses of welded joints. The bushings, when properly fitted and secured, maintain the structural integrity and rigidity of the connection without creating stress concentrations or heat-affected zones that lead to fatigue and cracking in welded joints.
Data Source
AI summary
A twist axle assembly (20) of a vehicle includes a pair of trailing arms (22) and a twist beam (24) extending along an axis (A) between first and second twist beam ends (26, 28). The twist axle assembly (20) further includes a bushing (38) interconnected to each one of the first and second twist beam ends (26, 28) and a respective trailing arm (22) for establishing a weld-less joint between the twist beam (24) and the trailing arm (24). In an embodiment, the twist beam (24) and bushings (38) are tubular, and the bushings (38) are press-fit or molded onto the respective first or second twist beam ends (36, 38). In a further embodiment, the trailing arms (26) define an orifice (40) aligned on the axis (A), and the tubular bushings (38) are press-fit into the orifices (40) of the trailing arms (26) to establish the weld-less joint.