Vehicle Body Side Frame Overlap Welding for Closed-Section Strength
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Solution Overview
Problem
Existing methods for manufacturing vehicle body side structural frames face issues such as reduced mechanical properties in weld zones due to aluminum-silicon coatings, increased production costs from additional coating removal steps, and structural weaknesses due to incomplete closure of sections like the A-pillar and rocker, which compromise the frame's strength during crashes.
Innovation Solution
A method involving the formation of a unitary body side structural frame by partially overlapping blanks and welding them in specific regions to create increased thickness and strength, eliminating the need for coating removal and using alternative welding techniques like spot welding or remote laser welding, while ensuring complete closure and enhanced stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If blanks with aluminum-silicon coating are welded to form a tailor welded blank, then the weight of components is minimized while respecting structural requirements, but the mechanical properties of the weld zone are reduced and the possibility of fracture increases
Solution Approach 1:
The patent removes the aluminum-silicon coating from the welding zone before welding. This extraction of the harmful coating layer eliminates the source of mechanical property degradation in the weld zone, allowing the welded blank to achieve both weight minimization and adequate weld strength.
Solution Approach 2:
The coating removal is performed as a preliminary step before welding. By removing the aluminum-silicon coating in advance, the welding process can proceed without the harmful effects of the coating, ensuring proper weld quality and mechanical properties from the start.
2Strength
If aluminum-silicon coating is removed by laser ablation, then the mechanical properties of the weld zone are improved, but the production cost increases and the process complexity increases
Solution Approach 1:
The patent employs a cost-effective coating removal method that is simpler and more economical than laser ablation. This approach achieves the necessary coating removal at lower production costs and with reduced process complexity, making the manufacturing process more viable for industrial application.
3Ease of manufacture
If sections like A-pillar and rocker are not completely closed, then the manufacturing process is simplified, but the structural strength during crashes is compromised
Solution Approach 1:
The patent forms the A-pillar and rocker as a unitary structure from a single welded blank, merging these sections into one continuous piece. This eliminates gaps and ensures complete closure, significantly improving structural strength during crashes while maintaining manufacturing efficiency through the integrated forming process.
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 structural integrity and strength of the vehicle frame, particularly in high-load areas, reduces production costs, and improves manufacturing efficiency by minimizing material waste and complex quality processes.
Implementation Method 1
joining the blanks to each other to form a composite blank, wherein joining the blanks includes forming one or more overlapping regions formed by partially overlapping at least two blanks
Implementation Method 2
shaping the composite blank, e.g. by hot forming or cold forming
Implementation Method 3
shaping the composite blank, e.g. by hot forming or cold forming
Implementation Method 4
using alternative welding techniques like spot welding or remote laser welding
Implementation Method 5
using alternative welding techniques like spot welding or remote laser welding
Data Source
Figure 1~2
Figure 3~4
Figure 5~6A
AI summary
A method for manufacturing a unitary body side structural frame for a vehicle is provided. The method comprises providing a plurality of blanks, joining the blanks to each other to form a composite blank wherein joining the blanks includes forming one or more overlapping regions formed by partially overlapping two blanks and deforming the composite blank to form the unitary body side structural frame. A unitary body side structural frame as obtained by any of the methods herein described is also provided.