Beaded Box Profile Assembly for Vehicle Restraint Sections
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Solution Overview
Problem
Existing box profiles for vehicle restraint systems face challenges in manufacturing technology, particularly in the assembly and connection of box sections, which are complex and inefficient.
Innovation Solution
A box profile with a U-shaped cross-section and tapered end section, featuring a cross-section-reducing bead, allows for efficient assembly by sliding and connecting with non-tapered end sections using connecting means, and a method involving roll forming and press forming to produce high-quality box profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If box sections are assembled by connecting tapered end sections to non-tapered end sections, then the containment level and structural integrity are improved, but the manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The box profile is divided into modular sections with standardized tapered end sections that can be independently manufactured and then assembled together, reducing overall manufacturing complexity while maintaining structural integrity
Solution Approach 2:
The tapered end section of one box profile is inserted into the non-tapered end section of another box profile, creating a nested connection that simplifies assembly while ensuring strong structural bonding
2Ease of operation
If tapered end sections are used for connection, then the ease of assembly is improved, but the manufacturing precision requirements worsen
Solution Approach 1:
The tapered end section uses specific geometric parameters (taper angle, length, and cross-sectional dimensions) that are optimized to balance ease of assembly with manufacturability, allowing for tolerant assembly while maintaining connection strength
3Manufacturing precision
If complex manufacturing methods are used to produce box profiles, then the manufacturing precision is improved, but the productivity decreases
Solution Approach 1:
The box profiles are designed with pre-formed tapered end sections that can be manufactured using standardized preliminary forming processes, eliminating the need for complex post-manufacturing operations and improving overall production efficiency
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 solution enables rational and efficient manufacturing of box profiles that meet high performance standards, facilitating easy assembly and connection, resulting in a cost-effective and high-quality vehicle restraint system.
Implementation Method 1
The tapering of the end section is created by a bead that reduces the cross-section. By forming the bead into the end section, the end section is tapered and reduced in cross-section
Implementation Method 2
clamping the end section in the press and displacing the punch and the die relative to one another while forming a bead in the end section
Data Source
Figure 1a~1e
Figure 2a~2e
Figure 3a~3c
AI summary
The invention relates to a box profile 1 for a vehicle restraint system, a vehicle restraint system comprising such a box profile 1, and a method for producing a box profile 1. A box profile 1 has a box body 3 with a U-shaped cross-section and a tapered end section 5. The taper of the end section 5 is created by a bead 12 that reduces the cross-section of the end section 5. The end section 5 is tapered and reduced in cross-section by the molding and formation of the bead 12 such that the tapered end section 5 can be received in a form-fitting manner in a non-tapered end section 6 of another box profile 1. Several box profiles 1 are joined together in a vehicle restraint system in sections.