Heavy-Duty Vehicle Frame Vertical Cross-Brace Load Dissipation
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Solution Overview
Problem
Conventional heavy-duty vehicle frames are heavy, inefficient in reacting lateral and longitudinal loads, and require numerous gussets and braces, which increase weight and manufacturing costs while reducing cargo capacity.
Innovation Solution
The frame design incorporates vertical cross-brace structures between main members and hangers, reducing the need for heavy cross members and gussets, and utilizing a truss-like configuration to efficiently react loads through compression and tension, thereby minimizing weight and cost while enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional rigid main members and cross members are used to control vertical loads, then vertical load bearing capacity is improved, but the frame weight increases and lateral and longitudinal load resistance remains insufficient
Solution Approach 1:
The frame is segmented into specialized load-bearing elements: main members for vertical loads, cross members for lateral loads, and longitudinal members for longitudinal loads. This segmentation allows each element to be optimized for its specific function, reducing overall weight while maintaining strength.
Solution Approach 2:
Different parts of the frame have different structural qualities tailored to their specific load requirements. The main members have rigid vertical orientation for vertical loads, cross members have horizontal orientation for lateral loads, and longitudinal members provide longitudinal stability. This local optimization reduces unnecessary material in each region.
2Stability of the object's composition
If numerous gussets, braces and additional bracing structures are added to minimize lateral and longitudinal loads, then load distribution is improved, but the frame weight and manufacturing cost increase
Solution Approach 1:
The bracing system is segmented into distinct functional components: cross members for lateral loads, longitudinal members for longitudinal loads, and gussets for load distribution at joints. This segmentation eliminates redundant bracing while ensuring comprehensive load coverage.
Solution Approach 2:
The cross members serve multiple functions: they provide lateral load resistance, act as attachment points for gussets, and work with longitudinal members to provide longitudinal stability. This multi-functionality reduces the need for separate dedicated components.
3Reliability
If heavy cross members and gussets are used to support axle/suspension systems, then structural durability is improved, but the available payload capacity is reduced
Solution Approach 1:
The support structure is segmented into specialized elements: main members for vertical support, cross members for lateral stability, and gussets for localized reinforcement. This segmentation allows durable support where needed while minimizing unnecessary material throughout the structure.
Solution Approach 2:
The frame design optimizes structural parameters (member dimensions, material properties, geometric configuration) to achieve maximum durability with minimum weight. The I-shaped cross sections and optimized joint configurations provide high strength-to-weight ratios.
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
The design results in a stronger, lighter, and more cost-effective frame that efficiently handles vertical, lateral, and longitudinal loads, increasing payload capacity and simplifying the manufacturing process.
Implementation Method 1
utilizing a truss-like configuration to efficiently react loads through compression and tension
Implementation Method 2
utilizing a truss-like configuration to efficiently react loads through compression and tension
Data Source
AI summary
A frame for a heavy-duty vehicle includes a pair of spaced-apart, parallel, elongated and longitudinally extending main members. Each one of a pair of hangers is attached to and depends below a respective one of the main members. An axle/suspension system is mounted on the hangers. A vertically disposed brace structure extends between and is attached to the hangers and the main members. The brace structure includes a hanger cross member disposed perpendicularly between the hangers and a pair of inclined members each of which extend between and are attached to the hanger cross member and to a respective one of the main members or to a respective one of the main members and a respective one of the hangers. The brace structure efficiently dissipates loads from the axle/suspension system into the frame adjacent the hangers and eliminates the need for additional cross members within the frame.