Cockpit Cross-Member Fastening Layout for Simpler Assembly
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Solution Overview
Problem
Existing methods for producing structural components, such as cockpit cross-members for motor vehicles, are often complex and costly, lacking efficient solutions for simple and cost-effective production.
Innovation Solution
A structural component comprising a profile element with a peripheral wall and through openings, combined with fastening elements and forming portions that position the fastening elements with respect to the openings, allowing for fixed positioning and prevention of slippage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If existing methods are used for producing structural components, then the components can be produced, but the production process is complex and costly
Solution Approach 1:
The patent combines multiple functions into a single integrated profile element: the structural component, the fastening element positioning, and the forming portions are all incorporated into one extruded profile. This merging eliminates the need for separate assembly steps and reduces production complexity while maintaining manufacturing capability.
Solution Approach 2:
The forming portions are pre-integrated into the profile element during the extrusion process, before the final assembly. This preliminary action of creating the forming portions as part of the base profile simplifies subsequent manufacturing steps and reduces overall production complexity.
2Ease of manufacture
If existing methods are used for producing structural components, then the components can be produced, but the production cost is high
Solution Approach 1:
The patent utilizes material reservoirs with varying thicknesses (first thickness in the wall, second thickness in the reservoir) to optimize material distribution. This parameter change allows concentrated material where forming is needed while reducing material in other areas, achieving cost-effective production without excessive material consumption.
Solution Approach 2:
The forming portions are created using localized material reservoirs at specific positions along the profile element, rather than uniformly thick material throughout. This local quality approach ensures material is provided only where needed for forming, reducing overall material costs while maintaining production effectiveness.
3Strength
If forming portions are created without material reservoirs, then the production process is simpler, but the structural integrity is impaired
Solution Approach 1:
The material reservoirs are pre-formed as integral parts of the profile element during extrusion, before the final forming operation. This preliminary preparation ensures that sufficient material is available at the correct locations to maintain structural integrity during subsequent forming, without adding complex assembly steps.
Solution Approach 2:
The material reservoirs and forming portions are merged into a single integrated feature of the profile element. This combination ensures that the structural integrity is maintained by having the reservoirs as part of the load-bearing structure, while avoiding the complexity of separate reinforcement components.
4Reliability
If fastening elements are not precisely positioned, then the assembly is simpler, but the structural component reliability is reduced
Solution Approach 1:
The forming portions automatically position the fastening elements during the forming process itself. As the material is formed, it naturally guides and positions the fastening elements at the correct locations, eliminating the need for separate positioning mechanisms or complex alignment procedures while ensuring reliable positioning accuracy.
Solution Approach 2:
The forming portions are designed with predetermined geometries that guide the fastening elements into correct positions before final setting. This preliminary positioning action is built into the forming process, ensuring accurate fastening element placement without requiring additional positioning steps or complex mechanisms.
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 solution enables the production of structural components in a simple and cost-effective manner, ensuring fixed positioning of fastening elements and enhancing structural integrity.
Implementation Method 1
the at least one forming portion is configured by plastic forming of a material reservoir provided on the profile element and/or on the at least one fastening element
Data Source
AI summary
In order to provide a structural component, in particular a cockpit cross-member for a motor vehicle, which can be produced simply and cost-effectively, according to the invention the structural component comprises the following: a profile element which has a peripheral wall that delimits an interior of the profile element at least in regions, and at least one through opening provided in the peripheral wall of the profile element; at least one fastening element which is arranged in the interior of the profile element so as to correspond to the at least one through opening; and at least one pressure-forming portion which is formed on the profile element and/or on the fastening element and positions the fastening element with respect to the through opening.