Motor-vehicle Front Structure Beam and Plate Connection
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Solution Overview
Problem
Conventional methods for connecting a motor-vehicle front structure's longitudinal beam and front plate face challenges in achieving a balance between simplicity of manufacture, precision of assembly, and high mechanical strength, particularly due to manufacturing tolerances.
Innovation Solution
A unit comprising a hollow longitudinal beam with two beam elements and a front plate connected via separate C-shaped and L-shaped flanges, welded using spot electric welds, allowing for adjustments and reliable connections despite dimensional variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional welding methods with preliminary cutting operations are used to connect the front plate to the longitudinal beam, then the connection strength is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The connection system is segmented into modular components: the front plate with integrated flanges, the longitudinal beam with positioning features, and separate welding fixtures. This segmentation allows each component to be manufactured independently with standard tolerances, eliminating the need for complex preliminary cutting operations while maintaining connection strength through the modular assembly process
Solution Approach 2:
Positioning fixtures and alignment features act as intermediaries between the front plate and longitudinal beam during assembly. These intermediaries ensure precise relative positioning and proper alignment before welding occurs, enabling strong connections without requiring high-precision preliminary cutting of the beam, thus reducing manufacturing complexity
2Strength
If conventional welding methods with preliminary cutting operations are used to connect the front plate to the longitudinal beam, then the connection strength is improved, but the manufacturing time and cost increase
Solution Approach 1:
Flanges are preliminarily attached to the front plate during its manufacturing process, and positioning features are pre-formed on the longitudinal beam. This preliminary action ensures that when the components are assembled, they are ready for immediate welding without requiring time-consuming preliminary cutting operations, thus improving manufacturing efficiency while maintaining connection strength
Solution Approach 2:
The invention changes the tolerance parameters from tight (requiring preliminary cutting) to standard manufacturing tolerances. By designing the connection system to accommodate standard tolerances through flanges and positioning features, the manufacturing time is reduced while maintaining adequate connection strength for the application
3Ease of manufacture
If standard manufacturing tolerances are used without preliminary cutting, then the manufacturing simplicity is improved, but the connection precision deteriorates
Solution Approach 1:
Positioning fixtures serve as intermediaries that compensate for variations within standard manufacturing tolerances. These fixtures ensure that the front plate and longitudinal beam are precisely aligned during assembly, achieving the required assembly precision while allowing both components to be manufactured with simpler, standard tolerances
Solution Approach 2:
The flanges attached to the front plate serve multiple functions: they provide welding surfaces for connection to the beam, act as positioning elements for alignment, and serve as reinforcement structures. This multi-functionality enables the use of standard manufacturing tolerances while maintaining assembly precision, as the flanges compensate for dimensional variations
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 enables a cost-effective, reliable, and strong connection with reduced manufacturing costs and improved collision absorption capabilities, while accommodating variations in manufacturing tolerances.
Implementation Method 1
said first and second flanges welded to a rear face of the front plate for connection of a front end of the longitudinal beam
Implementation Method 2
welded using spot electric welds
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Unit with longitudinal beam and front plate for a motor-vehicle front structure, comprising a longitudinal beam (2) in the form of a hollow profile and a front plate (3) rigidly connected to a front end of said longitudinal beam (2). The longitudinal beam (2) comprises a first beam element (21) defining an upper wall (211), a lower wall (212) and a first side wall (213) of the longitudinal beam (2) and a second beam element (22) having a wall defining a second side wall (221) of the longitudinal beam (2). The front plate (3) has a rear face (3B) facing towards the longitudinal beam (2) to which there are welded a first flange (6) and a second flange (7) which are separate from each other, for connecting the front end of the longitudinal beam (2). The first flange (6) is a C-shaped bracket with an upper wall (61), a lower wall (62) and a side wall (63) respectively welded to the upper wall (211), the lower wall (212) and the first side wall (213) defined by said first beam element (21). The second flange (7) is an L-shaped bracket, with a first wall (71) welded to the rear face (3B) of the front plate (3) and a second wall (72) facing towards said second side wall (221) defined by said second beam element (22). The above mentioned welds are electric spot welds. The two flanges (6,7) may have different thickness.