Boxed Frame Member Assembly with Locator Spacer Alignment
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Solution Overview
Problem
Existing frame structures in automotive applications face challenges in achieving equal or greater strength and torsional stability while reducing assembly costs and improving manufacturing efficiency.
Innovation Solution
A box-type structural assembly with a first and second section having webs and flanges, where at least one spacer is positioned between the webs, and locators engage the spacer to fix its position, allowing for secure welding and alignment, thereby enhancing strength and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional frame structures are used, then assembly is simpler, but strength and torsional stability are insufficient
Solution Approach 1:
The frame structure is divided into modular sections with standardized spacers and locators, allowing complex strength requirements to be achieved through repeated simple units rather than monolithic complex structures
Solution Approach 2:
Locators are pre-positioned on the frame sections to guide spacer placement before welding occurs, ensuring precise alignment is achieved during assembly rather than requiring complex post-assembly adjustments
2Strength
If more spacers are added to improve strength, then frame strength increases, but assembly time and cost increase
Solution Approach 1:
The locators automatically guide spacer placement and self-align components during assembly, eliminating the need for manual measurement and alignment operations that slow down assembly
Solution Approach 2:
Locators serve as intermediary elements between frame sections and spacers, facilitating quick and accurate spacer installation without requiring complex alignment procedures or specialized tools
3Manufacturing precision
If precise spacer alignment is achieved through manual methods, then positioning accuracy is sufficient, but manufacturing cost and time increase
Solution Approach 1:
Locators act as intermediary positioning elements that translate frame section geometry into precise spacer locations, achieving high manufacturing precision through simple mechanical guidance rather than complex measurement and adjustment procedures
4Weight of moving object
If frame weight is reduced for efficiency, then fuel economy improves, but strength and fatigue resistance decrease
Solution Approach 1:
The frame is segmented into sections connected by standardized spacers, allowing weight optimization through modular design where each section can be independently sized and material-selected for minimum weight while maintaining overall structural strength
Solution Approach 2:
The combination of frame sections, spacers, and locators creates a composite structural system where the interaction between components provides enhanced strength-to-weight ratio compared to traditional monolithic frame designs
Data Source
AI summary
A box-type frame member assembly, and a method for assembling the box-type frame member. A first section, having a web, a pair of flanges and a number of holes with locators, is placed onto a fixture assembly with the holes fitting onto pilots. A spacer is placed over each of the pilots and engaged with the locator of the respective hole in the first section. A second section, having a web, a pair of flanges, and a number of holes with locators, is then placed onto the fixture assembly with the holes fitting onto the pilots, and second end of each spacer is engaged with the locator associated with the web of the second section. Finally, the flanges of the first and second sections are secured together.