Accumulator Shell Structure With Thickened Weld Zone and Lower Weight
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Solution Overview
Problem
The existing accumulator shell members face durability issues due to stress concentration at the welds under high pressure, leading to potential breakage, and increasing weld thickness to improve durability results in increased weight, affecting fuel efficiency.
Innovation Solution
A shell member design with a thicker second wall portion than the first wall portion, allowing for increased weld thickness to enhance durability while maintaining a thinner profile elsewhere to reduce weight, and a taper portion for easier production and stress distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of the shell member at the weld is increased to improve durability, then the weld is less likely to break under stress, but the weight of the accumulator is increased
Solution Approach 1:
The shell member is designed with non-uniform thickness, where the second wall portion at the weld location has greater thickness than the first wall portion. This local quality variation allows the weld area to have enhanced durability while other portions maintain thinner profiles, thus improving reliability without significantly increasing overall weight.
2Strength
If the thickness of the shell member is increased to improve weld strength, then the weld can withstand higher stress, but the weight of the vehicle is increased, reducing fuel efficiency
Solution Approach 1:
The shell member implements localized thickness enhancement only at the second wall portion where the weld is located. This ensures sufficient weld strength to withstand high stress while avoiding unnecessary weight increase in other areas, thereby maintaining fuel efficiency.
3Ease of manufacture
If the shell member has uniform thickness, then the manufacturing process is simpler, but the weld becomes a weak point under high pressure
Solution Approach 1:
The shell member transitions from uniform thickness to non-uniform thickness, with the second wall portion having greater thickness than the first wall portion. This design prioritizes weld durability at the critical joint area while accepting increased manufacturing complexity, as the non-uniform thickness can be achieved through controlled forming processes.
Data Source
AI summary
A shell member 10 constituting an accumulator 100 including a cover member 30, a shell member 10 having a cylindrical portion 11, an opening portion 13 formed at one end of the cylindrical portion 11 and welded to the cover member 30, and a closed portion 12 formed at another end of the cylindrical portion 11, and an accumulation part 70 accommodated in the shell member 10. The cylindrical portion 11 includes an upper end portion 11a, and a protruding portion 11c having the opening portion 13. The protruding portion 11c is thicker than the upper end portion 11a.