Vehicle Carrier Half-Shell Joint for Single-Stage Welding
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Solution Overview
Problem
Existing carrier components for vehicle applications face challenges with weight optimization, processing time, and stiffness due to double-layer material and complex welding requirements, particularly in producing components with smaller dimensions and continuous sealed designs.
Innovation Solution
A carrier component formed by two U-shaped half-shells welded at contact sides, where the lower half-shell's point of contact protrudes outward and the upper half-shell's point of contact protrudes inward, allowing for a single-stage welding process with minimal protrusion (≥0.1 mm) to prevent weld pool flow-off and enhance weld seam quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two half-shells are connected with overlapping connection, then the joint connection is achieved, but the weight increases due to double layer of material
Solution Approach 1:
The patent applies asymmetry by creating an asymmetric joint configuration where one half-shell has an outward protruding point of contact and the other has an inward protruding point of contact. This asymmetric design eliminates the double-layer material overlap, reducing weight while maintaining structural integrity and weldability.
2Weight of moving object
If two half-shells are welded in I-joint configuration, then the weight is reduced, but the processing time increases due to two-stage welding
Solution Approach 1:
The patent applies preliminary action by pre-forming protruding points of contact on both half-shells before assembly. This preliminary preparation enables single-stage welding by ensuring proper alignment and contact geometry is already established, eliminating the need for time-consuming two-stage welding processes.
3Loss of time
If single-stage welding is performed, then the processing time is reduced, but the weld quality deteriorates due to welding from side or overhead position
Solution Approach 1:
The patent applies dimensionality change by transitioning from traditional side or overhead welding positions to a vertical welding configuration. The protruding point of contact arrangement enables the welding torch to approach from above, utilizing gravity to contain the weld pool and allowing single-stage welding with high-quality results.
4Device complexity
If single-sided welding is performed, then the device complexity is reduced, but the component twisting increases due to torsion in direction of weld seam
Solution Approach 1:
The patent converts the potential harm of single-sided welding-induced torsion into a benefit by strategically positioning the protruding point of contact. The geometry of the protrusion is designed to naturally counteract twisting forces during welding, allowing single-sided welding to proceed without significant component distortion.
5Reliability
If the point of contact protrusion is increased, then the weld pool containment is improved, but the material usage increases
Solution Approach 1:
The patent applies parameter changes by optimizing the protrusion dimensions to a minimal effective size. The protruding point of contact is designed with specific geometric parameters that provide sufficient weld pool containment while minimizing material consumption, achieving the optimal balance between weld reliability and material efficiency.
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 reduces weight, minimizes twisting during welding, and achieves high-quality welds with reduced energy input, suitable for producing components with thinner walls and optimizing weight distribution while maintaining strength and stiffness.
Implementation Method 1
the point of contact of the lower half-shell protrudes in relation to the external closed side of the other half-shell... to prevent weld pool flow-off
Implementation Method 2
two half-shells that are welded to one another at contact sides
Data Source
AI summary
A carrier component for a vehicle application, formed by two half-shells that are welded to one another at contact sides. When assembling the two half-shells for joining same at the contact sides, in a position in which the two half-shells are arranged above one another, the point of contact of the lower half-shell protrudes in relation to the external closed side of the other half-shell. The point of contact of one of the two half-shells protrudes inward in relation to the internal closed side of the other half-shell. A method for producing a carrier component from two half-shells is also disclosed.