Twist Beam Axle Gusset Structure With Variable Thickness
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Solution Overview
Problem
Existing torsional axles in motor vehicles are costly due to excess material in less stressed areas, leading to unnecessary weight and fuel consumption.
Innovation Solution
A torsional axle structure with a U-shaped cross member and a longitudinal connecting piece (gusset) featuring varying thicknesses, thicker where stress is high and thinner where stress is low, reducing material usage and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If constant thickness metal strips are used for cross member and connecting pieces, then fatigue and wheel impact resistance criteria are met in most stressed areas, but excess material is used in less stressed areas increasing cost and weight
Solution Approach 1:
The patent applies local quality by varying the thickness of metal strips used in the cross member and connecting pieces. The metal strips have different thicknesses in different regions: thicker in high-stress areas (such as near the arms and mounting points) to meet fatigue and impact resistance criteria, and thinner in low-stress areas to reduce material usage. This localized variation in thickness optimizes both structural reliability and material efficiency.
2Strength
If constant thickness metal strips are used for cross member and connecting pieces, then structural integrity is maintained, but vehicle weight increases leading to higher fuel consumption
Solution Approach 1:
The patent implements local quality by designing the cross member and connecting pieces with non-uniform thickness distribution. The metal strips are thicker where structural integrity is critical (at stress concentration points and connection areas) and thinner where less strength is required. This approach maintains the necessary structural integrity while minimizing the overall weight of the axle assembly, thereby reducing fuel consumption.
Data Source
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AI summary
The invention relates to a torsional axle structure comprising: a U-shaped profiled cross member having a bottom and two free flanges (28, 30), and two opposite cross member ends (15, 22), each of said two ends having two flange edges, said flange edges each having a notch; a hollow arm (14) connected to each of said two ends (15, 22) and extending into the notches; a connecting piece (32) having two opposite piece ends (44, 46) and two opposite longitudinal edges (48, 50), and mounted to each of said two cross member ends (15, 22) such that said two opposite longitudinal edges (48, 50) are respectively connected to said flanges (28, 30), while one (46) of said two piece ends is connected to said arm (14). Said connecting piece (32) has a decreasing thickness from said one (46) of said two ends of piece connected to said arm (14) to the other (44) end of piece.