Bicycle Frame Unit with Inclined Flange Joining
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Solution Overview
Problem
The existing frame units for bicycles face issues with residual stress and aesthetic deterioration due to welding, leading to safety concerns and reduced productivity, as well as inconsistent quality and prolonged working times in the manufacturing process.
Innovation Solution
The integration of left and right frame bodies, each comprising parts of the head tube, seat tube, and stays, with inclined flanges and a V-shaped joining groove for welding, allowing for automated welding and improved joint strength, while minimizing weld bead exposure and enhancing aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding process is used to join head tube, seat tube, frame, and stays, then components can be securely connected, but residual stress and cracks occur at joining portions reducing safety
Solution Approach 1:
The frame is divided into left and right frame bodies that are press-formed separately and then joined. This segmentation allows for more uniform stress distribution at the joining portions compared to traditional welding of multiple individual components, reducing residual stress and crack formation while maintaining joint strength
Solution Approach 2:
The joining portion is designed with specific geometric parameters including an inclined surface with a predetermined angle and a curved surface with a predetermined radius of curvature. These parameter changes optimize stress distribution and eliminate stress concentration points, preventing cracks while maintaining secure connection
2Strength
If manual welding is performed to join frame components, then components can be connected, but welding quality varies with worker skill and environment reducing productivity
Solution Approach 1:
The left and right frame bodies are press-formed with predetermined joining portion geometries (inclined surfaces and curved surfaces) before assembly. This preliminary action ensures that when components are joined, the optimal stress distribution is already built-in, eliminating the need for skilled manual welding adjustments and enabling automated, consistent joining processes that improve productivity
3Strength
If welding is used to join frame components, then structural integrity is achieved, but weld beads protrude causing aesthetic deterioration
Solution Approach 1:
The joining portion is designed with a curved surface having a predetermined radius of curvature that allows weld beads to be contained within the curve. This parameter change enables the welding process to maintain structural integrity while the curved geometry conceals or minimizes the visual impact of weld beads, preserving aesthetic appearance
4Stability of the object's composition
If multiple frame components are joined by welding, then complete frame structure is formed, but excessive working time is required and quality consistency deteriorates
Solution Approach 1:
The frame is segmented into left and right frame bodies that can be press-formed and prepared independently, then quickly assembled through a simplified joining process. This segmentation reduces the number of welding operations required compared to joining multiple individual components, significantly reducing working time while maintaining complete frame structure
Solution Approach 2:
The joining portions on left and right frame bodies are pre-formed with specific geometries (inclined surfaces and curved surfaces) during press-forming. This preliminary action eliminates the need for complex现场 welding operations, allowing for quick, consistent assembly that reduces working time while ensuring quality consistency across all frames
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 enhances the rigidity and durability of the bicycle frame, reduces the risk of cracks, improves manufacturing efficiency, and maintains safety while providing an aesthetically pleasing design.
Implementation Method 1
press-forming a left frame body so that a part of a head tube, a part of a seat tube, a part of a frame, and a left stay are integrally formed
Implementation Method 2
the left frame body and the right frame body are welded and coupled by inserting a filler metal into the joining groove portion
Data Source
AI summary
A frame unit for a bicycle includes: a left frame body in which a part of a head tube, a part of a seat tube, a part of a frame, and a left stay are integrally formed; and a right frame body in which a part of the head tube, a part of the seat tube, a part of the frame, and a right stay are integrally formed, in which the left frame body and the right frame body are coupled so as to integrally form the head tube, the seat tube, and the frame, flanges are formed to be inclined along edges of the left frame body and the right frame body, respectively, and the left frame body and the right frame body are coupled through the flanges.