Integrated Bus Frame Profile for Weight Reduction
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Solution Overview
Problem
Current bus frames are heavy, costly, and time-consuming to produce due to the need for numerous additional fastening elements and complex assembly processes, particularly at the upper corners where stresses are high, and existing profiles are not suitable for manufacturing from a single sheet of sheet metal.
Innovation Solution
A multifunctional longitudinal profile for bus frames that integrates fixing surfaces for both the upper wall and side wall, produced by folding and welding a single sheet of sheet metal, allowing for reduced additional fastening elements and easier assembly, while enhancing mechanical strength and reducing weight and production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional fastening elements are added to reinforce the frame at upper corners, then the mechanical strength is improved, but the weight and production time increase
Solution Approach 1:
The patent merges the functions of multiple separate components (profile, fastening elements, and structural reinforcements) into a single integrated profile. The profile includes integrated fixing surfaces for both upper wall and side wall, as well as integrated reinforcement elements, eliminating the need for separate fastening components and reducing overall weight while maintaining strength.
Solution Approach 2:
The profile is designed as a multi-functional component that simultaneously serves as a structural element, a fastening interface, and a reinforcement element. The single profile provides fixing surfaces for both upper wall and side wall attachments, incorporates reinforcement structures, and eliminates the need for multiple specialized components, thereby reducing weight and simplifying assembly.
2Strength
If additional fastening elements are added to reinforce the frame at upper corners, then the mechanical strength is improved, but the production time increases
Solution Approach 1:
The patent merges the functions of multiple separate components (profile, fastening elements, and structural reinforcements) into a single integrated profile. The profile includes integrated fixing surfaces for both upper wall and side wall, as well as integrated reinforcement elements, eliminating the need for separate fastening components and reducing overall weight while maintaining strength.
Solution Approach 2:
The reinforcement elements and fixing surfaces are pre-integrated into the profile during manufacturing, rather than being added during assembly. This preliminary integration of strengthening features eliminates subsequent assembly steps and reduces production time while ensuring the required mechanical strength is achieved.
3Strength
If the section or thickness of the profile is increased, then the mechanical strength is improved, but the weight and cost increase
Solution Approach 1:
Instead of uniformly increasing the profile section or thickness throughout, the patent applies local reinforcement only where needed. The integrated profile includes strategically positioned reinforcement elements at specific locations (such as upper corners and attachment points) to provide enhanced strength precisely where required, while maintaining lighter construction in non-critical areas.
Solution Approach 2:
The patent merges the functions of multiple separate components (profile, fastening elements, and structural reinforcements) into a single integrated profile. The profile includes integrated fixing surfaces for both upper wall and side wall, as well as integrated reinforcement elements, eliminating the need for separate fastening components and reducing overall weight while maintaining strength.
4Adaptability or versatility
If multiple separate components are used for frame construction, then the adaptability is improved, but the device complexity increases
Solution Approach 1:
The profile is designed as a multi-functional component that simultaneously serves as a structural element, a fastening interface, and a reinforcement element. The single profile provides fixing surfaces for both upper wall and side wall attachments, incorporates reinforcement structures, and eliminates the need for multiple specialized components, thereby reducing weight and simplifying assembly.
Solution Approach 2:
The integrated profile is designed with distinct functional zones (fixing surfaces for upper wall, fixing surfaces for side wall, reinforcement elements) that can be independently optimized and positioned, allowing for design flexibility while maintaining a single-component structure that reduces overall system complexity.
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
The profile reduces the number of fastening elements, decreases the frame's weight and production time, and improves mechanical strength by allowing for a more robust and cost-effective frame design, with integrated fixing surfaces facilitating easier installation of external covering elements.
Implementation Method 1
made by folding and welding a single sheet of sheet metal, the welding being carried out at the level of a face, called the inner face
Data Source
Figure 1a~1b
Figure 2~3
Figure 4~5
AI summary
The invention relates to a profile (100) for fixing an upper wall and a longitudinal side wall of a structure of a land vehicle for public passenger transport, with a closed cross-section, comprising: a first face (102) for fixing the upper wall; a second face (104) for fixing the side wall; and a so-called outer face (106) arranged between said first face (102) and second second face (104); characterised in that said outer face (106) comprises at least one surface (110) for fixing an outer cladding element (116), forming a step in said outer face (106) towards the inside of said profile. The invention also relates to a structure comprising such a profile and to a vehicle comprising such a structure.