Bumper Doublehat Cover Welded Stiffening Design
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Solution Overview
Problem
Existing bumper beams face challenges in controlling deformation behavior under collision stress, leading to potential collapse and inefficient energy absorption.
Innovation Solution
A hat-shaped bumper beam design with a welded cover inside the profile, which stiffens the cross-section and delays buckling, allowing for improved deformation and energy absorption by reinforcing the beam with specific depressions and using different fabrication techniques for the cover and hat-shaped profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the cover is welded to the sides of the hat-shaped profile inside the profile, then the beam cross section is stiffened and collapse of the sides is prevented, but the manufacturing complexity increases due to additional welding operations and assembly steps
Solution Approach 1:
The cover is welded to the sides of the hat-shaped profile inside the profile, merging the cover with the beam structure to create a unified, stiffened cross-section that prevents collapse under collision stress
Solution Approach 2:
The bumper beam is divided into separate components (hat-shaped profile and cover) that are manufactured independently and then assembled through welding, allowing for optimized manufacturing of each part while achieving the desired structural performance
2Weight of moving object
If the cover is recessed into the hat-shaped profile and welded to the sides, then energy absorption is enhanced and weight can be reduced through thinner sheets, but the manufacturing precision requirements increase due to the need for accurate positioning and welding
Solution Approach 1:
The cover is recessed into the hat-shaped profile at specific locations rather than spanning the entire length, allowing for localized reinforcement where it is most needed while reducing overall material usage and weight
Solution Approach 2:
The cover and hat-shaped profile are prepared with predetermined recesses and welding positions before assembly, allowing for precise positioning and reduced welding complexity during final assembly
3Shape
If the cover stiffens the beam cross section and delays buckling, then the beam can be designed with higher profile and smaller sheet thickness, but the device complexity increases due to the multi-component structure
Solution Approach 1:
The cover is positioned inside the hat-shaped profile rather than on the exterior, utilizing the internal space to provide stiffening without increasing the overall external dimensions of the beam
Solution Approach 2:
The cover is nested within the hat-shaped profile structure, with the cover recessed into the profile and welded to the sides, creating a compact, multi-layered structure that maximizes stiffness within the available space
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 design enhances energy absorption, enabling the use of higher profiles or thinner sheets, thereby reducing weight while maintaining performance and improving collision resistance.
Implementation Method 1
The cover is recessed in the hat-shaped profile and is welded to the sides 16 and 17 inside the hat-shaped profile, with welds 33 and 34
Implementation Method 2
Both the cover and the hat-shaped profile are fabricated from hot-formed or cold-formed steel
Implementation Method 3
the hat-shaped profile can be fabricated using the press-hardening technique
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A bumper beam has a hat-shaped profile (11) with a cover (12) which is recessed into the hat-shaped profile and is welded to the sides (16, 17) of the hat-shaped profile, inside the hat-shaped profile.