Adhesive-Bonded Node and Strut Assembly for Lighter Boom Structures
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The design of structural assemblies for work machines, such as boom arms in construction vehicles, requires significant strength, durability, and energy to handle heavy loads, but current methods like machining and welding are costly and energy-intensive, and result in heavy structures with high inertia.
Innovation Solution
A lightweight structural assembly using struts and node members with adhesive bonding, where the struts extend along a longitudinal axis and engage node cavities, reducing material usage and weight while maintaining strength through adhesive layers and strategic node configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional machining and welding methods are used to create strong structural assemblies, then strength and durability are improved, but weight and manufacturing cost increase significantly
Solution Approach 1:
The structural assembly is divided into separate node members and strut members that are assembled together using adhesive bonding. This segmentation allows for optimized individual component design and reduces the need for heavy welding operations, resulting in lighter overall structure while maintaining strength
Solution Approach 2:
The invention changes the bonding method from mechanical welding to chemical adhesive bonding. This parameter change in the joining process enables lighter materials and thinner sections to be used, reducing weight while maintaining structural integrity through the adhesive bond
2Strength
If traditional machining and welding methods are used, then structural strength is improved, but manufacturing complexity and energy consumption increase
Solution Approach 1:
By segmenting the structure into modular node and strut components that connect via adhesive bonding, the manufacturing process is simplified. Each component can be manufactured independently using less complex processes, and assembly requires no specialized welding equipment or skilled welders
Solution Approach 2:
The invention replaces the mechanical welding process with adhesive bonding. This substitution eliminates the need for complex welding machinery, heat control systems, and post-weld heat treatment equipment, significantly reducing manufacturing complexity while maintaining structural strength
3Reliability
If traditional welding methods are used, then structural integrity is improved, but energy consumption and manufacturing cost increase
Solution Approach 1:
The invention replaces energy-intensive welding operations with adhesive bonding, which consumes significantly less energy. The adhesive bonding process eliminates the need for high-temperature heat sources, reducing manufacturing energy consumption while maintaining structural integrity through proper adhesive selection and application
Solution Approach 2:
Changing the joining method from thermal welding to chemical adhesive bonding fundamentally alters the energy parameters of the manufacturing process. This parameter change reduces energy consumption by eliminating the need for sustained high-temperature heating while achieving comparable or superior joint strength through chemical bonding mechanisms
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
This solution reduces the weight and inertia of the structural assembly, increasing lifting capacity, fuel efficiency, and work machine acceleration, while simplifying manufacturing and reducing energy consumption and tooling costs.
Implementation Method 1
an adhesive bonding the first end portion and the second end portion of the at least one strut to the plurality of node members at the first node cavity of each of the plurality of node members
Data Source
AI summary
A structural assembly for a work machine and method of assembling a node and strut structure are provided. The assembly includes at least one strut extending along a longitudinal axis and having a first end portion and a second end portion opposite the first end portion. The assembly further includes node members. Each of the node members has a first node portion with a first node cavity. The first end portion of at least one strut is configured to engage the first node portion of one of the node members. The second end portion of at least one strut is configured to engage the first node portion of another node member. An adhesive bonds the first end portion and the second end portion of the strut to the node members at the first node cavity of each of the node members.