Wheel Assembly Boss Load Transfer for Weight Reduction
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Solution Overview
Problem
The weight of wheel assemblies in heavy-duty vehicles increases due to the use of steel in knuckles, upper, and lower brackets, which negatively affects fuel efficiency by increasing the overall vehicle weight.
Innovation Solution
The use of a boss in slip fit engagement with a bore to transfer loads between the knuckle and the bracket, allowing the knuckle to be made from lightweight materials like aluminum, reducing weight and improving clamping force without relying solely on fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the knuckle, upper bracket and lower bracket are manufactured from steel to adequately transfer load, then the load transfer capability is improved, but the weight of the wheel assembly increases
Solution Approach 1:
The invention divides the load transfer function into two distinct mechanisms: (1) fasteners provide clamping force to secure the bracket to the knuckle, and (2) a boss integrated into the bracket provides additional load transfer capability through direct structural engagement with the knuckle. This segmentation allows the use of lighter materials while maintaining adequate load transfer.
Solution Approach 2:
The invention employs composite construction by combining the fastener system (providing clamping force) with the boss structure (providing direct load transfer path). This composite approach enables the bracket to be made from lighter materials such as aluminum or composite materials while still achieving the required load transfer capability through the combined action of both load transfer mechanisms.
2Strength
If multiple fasteners are used to connect the bracket to the knuckle, then the connection strength is improved, but the clamping force applied by each fastener is reduced
Solution Approach 1:
The invention segments the connection system into two functional components: fasteners that provide clamping force to secure the assembly, and a boss structure that provides additional load transfer capability. This segmentation allows the fasteners to focus on providing adequate clamping force without being overloaded, while the boss handles a portion of the load transfer, effectively distributing the mechanical demands.
Solution Approach 2:
The boss acts as an intermediary load transfer element between the bracket and the knuckle. It provides an additional load path that complements the fastener system, allowing the fasteners to maintain their primary function of providing clamping force while the boss handles a significant portion of the load transfer, thereby preventing fastener overload.
Data Source
AI summary
A wheel assembly for a vehicle includes a knuckle having an upper end and a lower end. A bracket is mounted to one of the upper end and the lower end of the knuckle by a plurality of fasteners. A ball joint is mounted to the bracket and configured for attaching the wheel assembly to the vehicle. One of the knuckle and the bracket defines a boss and the other defines a bore. The boss is slideably disposed within the bore in slip fit engagement. The boss transfers a load between the knuckle and the bracket in both a vertical direction along a king pin axis and a horizontal direction along a longitudinal axis of the vehicle.