Arc and Node Extrusion Assembly for Complex A-Surface Geometry
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Solution Overview
Problem
Traditional methods for fabricating arcs with A-surfaces in metal extrusion structures are costly and inefficient, failing to effectively meet the requirements of aerodynamics, styling, and structural support in vehicle design.
Innovation Solution
The use of metal extrusions with elongated cavities and surfaces, connected along their length, and deformed using dynamic dies to form complex shapes that integrate with nodes, allowing for precise geometric fits and structural support while reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional methods are used to fabricate arcs with A-surfaces, then structural support and shape requirements can be met, but manufacturing costs and equipment requirements become excessively high
Solution Approach 1:
The arc structure is divided into two separate components: a first structure (cavity) and a second structure (elongated surface), which are manufactured independently and then connected. This segmentation allows each component to be produced using simpler, more cost-effective processes while maintaining the required geometric precision through dedicated forming operations.
Solution Approach 2:
The first structure with the elongated cavity is formed first, and then the second structure with the elongated surface is connected to it. The cavity can accommodate or nest with other components, allowing for integrated assembly that reduces manufacturing complexity and cost while preserving structural integrity.
2Shape
If complex shapes are formed to meet aerodynamics and styling requirements, then vehicle design objectives are achieved, but manufacturing complexity and equipment costs increase
Solution Approach 1:
The manufacturing process employs dynamic forming operations where the die configuration can be adjusted or changed during the forming process. This allows complex aerodynamic shapes to be achieved through controlled deformation of the metal extrusion using evolving die geometries, rather than requiring extremely complex static tooling.
Solution Approach 2:
The invention transitions from forming complex three-dimensional shapes directly to creating a two-dimensional elongated surface that is connected to a cavity structure. This dimensional simplification allows aerodynamic surfaces to be achieved through surface forming operations rather than complex volumetric shaping, reducing equipment requirements.
3Manufacturing precision
If single-direction deformation is used in manufacturing, then process simplicity is maintained, but complex geometric fits and structural requirements cannot be met
Solution Approach 1:
The deformation process is segmented into multiple independent forming operations: first deforming the cavity structure in one direction, then deforming the elongated surface in a different direction. This sequential multi-directional deformation allows complex geometric fits to be achieved through separate, more manageable forming steps rather than a single complex operation.
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 approach enables the creation of cost-effective, aerodynamically optimized, and structurally robust arc and node structures that meet complex shape and functional requirements, enhancing vehicle design and manufacturing efficiency.
Implementation Method 1
deforming the first structure in a first direction, and deforming the second structure in a second direction different than the first direction
Data Source
AI summary
A metal extrusion and nodes based structure is provided. The structure comprises one or more arc members connected by one or more node members, wherein the arc comprises (i) a wing feature which is configured to mate with one or more non-structural components, (ii) an internal passage feature which is configured to be inserted into a connecting feature of the corresponding node member, and (iii) one or more keying features formed from a mating interface with the corresponding node member.