Motor Vehicle Body Welding for Localized Crash Deformation
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Solution Overview
Problem
The existing method of producing motor vehicle bodies from high-strength steel components requires complex heat treatment for local softening in collision regions, necessitating specialized equipment and processes that are not readily available to the body manufacturer.
Innovation Solution
Using a welding robot to apply welding points or seams outside connection regions to reduce metal hardness, leveraging existing joining technology for local heat input and tempering, thereby softening specific areas of the body or body part for deformation in non-critical zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If specialized laser or thermal printer equipment is used for local heat treatment to soften metal components, then the local softening effect is achieved, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The welding device is made multi-functional by enabling it to perform both its primary function (joining metal components) and a secondary function (local heat treatment for softening). The welding device includes a control unit that can operate in different modes: welding mode for joining components and heat treatment mode for localized softening. This eliminates the need for separate specialized equipment while achieving the desired local hardness reduction.
Solution Approach 2:
The patent combines the heat treatment function with the welding device by integrating a heat treatment device with the welding device. The control unit can switch between welding operations and heat treatment operations, allowing both functions to be performed by a single integrated system. This merging reduces device complexity and manufacturing costs while maintaining the effectiveness of local softening.
2Strength
If multiple separate processes are used for component manufacturing and heat treatment, then specialized heat treatment can be achieved, but the manufacturing process complexity increases
Solution Approach 1:
The patent merges the heat treatment process with the welding process by using the same welding device for both operations. The control unit can perform welding operations to join components and then perform heat treatment operations on the same or different components without requiring separate equipment or complex process integration. This simplifies the manufacturing process while achieving the desired local softening effect.
Solution Approach 2:
The welding device is designed with multi-functionality, allowing it to perform both welding and heat treatment operations. The control unit can switch between different operational modes (welding mode and heat treatment mode) based on the required operation. This universal approach eliminates the need for separate specialized heat treatment processes and equipment, simplifying the overall manufacturing workflow.
3Strength
If the body is produced entirely from hardened high-strength steel, then the overall strength is maximized, but the ability to deform in collision regions is reduced
Solution Approach 1:
The patent applies local quality by creating regions of different hardness within the metal component. The control unit performs localized heat treatment on specific regions (such as deformation regions or connection regions) to reduce hardness locally while maintaining the hardened state in other regions. This results in a component with spatially varying properties: hardened areas for strength and softened areas for controlled deformation during collisions.
Solution Approach 2:
The patent changes the material parameter (hardness) in specific regions through localized heat treatment. The control unit applies heat to selected regions, causing tempering that reduces hardness from the original hardened state (e.g., HV 400-520) to a softer state (e.g., HV 220-270). This parameter change enables the component to have both high overall strength and localized deformation capability, as the softened regions can deform preferentially during impact while the hardened regions maintain structural integrity.
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 method allows for simplified production of defined deformation regions using standard welding tools, enabling adjustable strength reduction and shape design, enhancing crash performance by allowing controlled deformation in softened areas during collisions.
Implementation Method 1
a welding point or a welding seam is applied to the component at one or more positions outside the connection regions to locally reduce the strength of the metal
Implementation Method 2
the originally hardened structure is tempered via this local heat input and the hardness is thus decreased
Data Source
AI summary
A method for producing a body or a body part of a motor vehicle. The body or the body part includes multiple components made of metal, which are welded to one another in adjacent connection regions via welding points or welding seams. A welding point or a welding seam is applied to the component at one or more positions outside the connection regions, to locally reduce the strength of the metal.