Butt Jointed Hollow Structural Element via Laser Trimming
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Solution Overview
Problem
Existing methods for manufacturing closed section hollow elements, such as motor compartment rails and suspension control arms, rely on clamshell configurations with overlapping joints, which result in redundant material and limitations in achieving zero gap interfaces necessary for high-quality butt welds, especially in sheet metal press forming.
Innovation Solution
A closed section hollow element is constructed using press formed open section sheet metal components with parallel flanges, where five-axis laser cutting ensures a zero gap interface for a continuous laser butt weld, eliminating redundant material and achieving high dimensional integrity and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If overlapping joints or flange type joints are used in clamshell configurations, then weldability and manufacturing feasibility are improved, but redundant material is created and weight increases
Solution Approach 1:
The patent extracts and eliminates the redundant overlapping material or flange material from the traditional clamshell configuration. By removing these unnecessary material extensions, the design achieves a true butt joint where the two shell edges meet directly at their open edges, eliminating wasted material while maintaining weldability through proper edge preparation and positioning.
Solution Approach 2:
The patent changes the geometric parameters of the joint configuration from overlapping/flange arrangements to a precise butt joint arrangement. This involves controlling the edge geometry, thickness alignment, and positioning parameters to enable direct edge-to-edge contact with minimal or zero gap, transforming the joint type while maintaining manufacturability.
2Productivity
If zero gap interface is achieved for laser butt welding, then welding quality and speed are improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies preliminary actions during the press forming process to ensure the shell edges are pre-positioned and pre-aligned with the correct geometry and spacing. By incorporating alignment features, precision locating elements, and pre-formed edge geometries into the stamping dies and tooling, the components arrive at the welding stage already prepared for zero-gap joining, reducing the precision burden on the welding operation itself.
Solution Approach 2:
The patent replaces traditional mechanical gap adjustment methods with laser-based measurement and compensation systems. Laser scanners or sensors precisely measure the actual gap between components, and the welding system automatically compensates for minor variations in real-time, enabling zero-gap welding even with slight variations in component dimensions or positioning.
3Ease of operation
If conventional welding techniques are used, then ease of application is improved, but heat input and distortion increase
Solution Approach 1:
The patent substitutes conventional arc welding processes with laser welding technology. The laser beam delivers concentrated thermal energy with precise spatial control, creating a narrow heat-affected zone and minimizing overall heat input to the structure. This replacement maintains ease of operation through automated positioning and control systems while dramatically reducing thermal distortion and heat-affected zone size.
Solution Approach 2:
The patent applies local quality by concentrating the welding energy precisely at the joint line where it is needed, rather than distributing heat over a broad area. The laser beam's focused energy creates a deep, narrow penetration profile that welds the joint effectively while leaving the surrounding material relatively cool and undistorted, maintaining structural integrity elsewhere in the component.
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 reduces material usage and production costs, allows for variable cross-sectional designs, and enhances the quality and speed of the welding process, resulting in lighter and more cost-effective structural components.
Implementation Method 1
the upstanding and downstanding interface flanges are complementarily trimmed using five-axis laser cutting
Implementation Method 2
The upper sheet metal stamped component and lower sheet metal stamped component are then structurally attached along the zero gap interface by a continuous laser butt weld
Data Source
AI summary
A method is provided which forms a closed section hollow structural element by performing the following steps which include press forming an upper sheet metal component configured with two primary parallel downstanding interface flanges; press forming a lower sheet metal component configured with two primary parallel upstanding interface flanges; complementarily trimming the downstanding interface flanges and the upstanding interface flanges using five-axis laser cutting; and butt welding the interface flanges of the upper and lower sheet metal components to one another to form a continuous hollow structural element of variable cross section.