Vehicle Cross-Member Attachment Device Mass Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing motor vehicle attachment devices for driver's compartment cross members are heavy, require multiple parts, and are costly to manufacture, making it difficult to optimize structure for mass while maintaining quality and production efficiency.
Innovation Solution
The attachment device integrates first and second reinforcements extending from the attachment element, which are welded to the A-pillar inner panel, allowing for a single-part design that reduces material usage and simplifies manufacturing, while maintaining strength and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a housing forming an open or closed hollow body is used for attachment, then the attachment device provides sufficient strength and stability, but the mass of the attachment device becomes relatively significant
Solution Approach 1:
The attachment device is segmented into functional zones: a stamping zone forming the attachment element and reinforcement zones with increased thickness. This segmentation allows the structure to provide strength only where needed (at attachment points) rather than uniformly throughout the entire component, reducing overall mass while maintaining attachment strength.
Solution Approach 2:
The A-pillar inner panel features local quality variations with a stamping zone having base thickness and reinforcement zones having increased thickness (1.5-3 times the base thickness). This local quality approach concentrates material where structural strength is required for attachment while minimizing material usage in non-critical areas, resolving the contradiction between strength and mass.
2Adaptability or versatility
If two differently shaped attachment devices are used for left and right sides, then the attachment device fits specific side requirements, but the device complexity and manufacturing cost increase
Solution Approach 1:
The attachment device achieves universality through symmetric design where the stamping zone and reinforcement zones can be configured to provide identical attachment characteristics on both left and right sides. This single universal design replaces the need for two differently shaped devices, reducing device complexity and inventory requirements while maintaining the ability to fit specific side requirements through proper orientation and configuration.
3Ease of manufacture
If the attachment device is built into the A-pillar inner panel by stamping, then the manufacturing cost and production lead time are reduced, but the solution cannot be applied to all vehicle types
Solution Approach 1:
The attachment device incorporates dynamic adaptability through configurable reinforcement zones that can be adjusted in position, size, and thickness according to different vehicle types and impact requirements. This allows the same stamping-based manufacturing approach to be adapted across various vehicle platforms, maintaining ease of manufacture while achieving versatility across vehicle types.
Solution Approach 2:
The design allows parameter changes in the reinforcement zones (thickness, position, dimensions) to accommodate different vehicle types and safety requirements. By varying these parameters rather than changing the fundamental stamping manufacturing process, the solution maintains ease of manufacture while achieving adaptability across different vehicle applications.
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 solution reduces the mass of the attachment device by 0.5-0.8 kg and lowers manufacturing costs by enabling a single tool for both left and right-hand attachments, while maintaining structural integrity and improving impact resistance.
Implementation Method 1
at least one of the side walls of each of the first and second reinforcements is attached to the second face of the attachment element, in particular by a weld seam
Data Source
AI summary
The invention relates to a device for attaching an end of a cross-member of a driver's compartment of a motor vehicle to the assembled shell, which includes an attachment element provided with a first surface, for receiving the cross-member of a driver's compartment, and with a second surface opposite the first surface. Said device comprises first and second reinforcements extending from the second surface and each including: a base connected to the attachment element and to be attached to a portion of the vehicle, two side walls extending from the base and connected to the attachment element.