Vehicle Body Connection Using Bending-Stress Fixing Elements
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Solution Overview
Problem
In vehicle body manufacturing, the use of component-specific holding devices for connecting body parts is costly and occupies valuable production space, and existing connection methods require additional devices for permanent fixation, especially when components lack inherent rigidity.
Innovation Solution
A component connection system using detachable pairs of fixing elements, where the male and female elements are arranged to apply bending stress, allowing components to be pre-fixed without component-specific holding devices, and subsequently permanently connected through welding or other methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If component-specific holding devices are used to connect body parts, then reliable connection and precise alignment are achieved, but high initial investments and occupation of valuable production space occur
Solution Approach 1:
The holding device is segmented into multiple independent fixing elements (male and female) that can be distributed at different positions on the components. Each fixing element acts as an independent unit that contributes to the overall connection stability, eliminating the need for a single complex holding device
Solution Approach 2:
The fixing elements are designed with universal applicability - the male fixing element with spherical head and the corresponding female fixing element with hole can be used for different component geometries. This multi-functional design replaces the need for component-specific customized holding devices
2Stability of the object's composition
If component-specific holding devices are used for permanent fixation, then stable connection is achieved, but additional costs and production space occupation occur
Solution Approach 1:
The fixing elements are integrated directly into the components themselves - male fixing elements are attached to one component and female fixing elements to the other component. This merging eliminates the need for separate external holding devices, reducing both quantity and cost while maintaining connection stability
Solution Approach 2:
The components themselves provide the fixing elements needed for connection. The male and female fixing elements are part of the component structure, allowing the components to self-fixate without requiring external holding devices, thereby reducing the number of additional devices needed
3Manufacturing precision
If multiple fixing elements are used to connect components, then component alignment and curvature control are improved, but the complexity of the connection system increases
Solution Approach 1:
Different fixing elements are positioned at specific locations on the components to address local geometric requirements. The male fixing element with spherical head provides rotational freedom at its specific location while maintaining positional constraint, allowing precise alignment control without requiring complex overall system design
Solution Approach 2:
The male fixing element features a spherical head that can rotate freely within the female fixing element's hole. This spherical geometry provides automatic alignment capability and accommodates curvature variations in the components, simplifying the connection system while maintaining manufacturing precision
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
Enables efficient, space-saving, and cost-effective assembly of vehicle components by eliminating the need for additional clamping devices during welding, ensuring precise alignment and curvature of components without additional tensioning or clamping devices.
Implementation Method 1
A component connection is proposed, in which two or more components (1, 3) are detachably connected to one another by means of at least two pairs of fixing elements (2a, 2b, 2c and 4a, 4b, 4c)
Implementation Method 2
The fixing elements are arranged in such a way that, when the two components are detachably connected by means of the pairs of fixing elements, a bending stress that bends or curves the components results in both components
Data Source
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AI summary
A connection between components includes a first component, a second component, and at least two pairs of fixing elements spaced apart by which the two components are detachably connected. Each pair of fixing elements has a female fixing element and a male fixing element that is inserted into the female fixing element. A fixing element of each pair of fixing elements is provided on the first component and the other fixing element of each pair of fixing elements is provided on the second component. The fixing elements are arranged such that on detachable connection of the two components by the pairs of fixing elements in the two components, a bending stress results in the components.