Vehicle Crossmember End Plate Weld Layout for Impact Rotation
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Solution Overview
Problem
Existing absorption devices in land vehicles suffer from weld bead stress and component rotation issues during impacts, leading to potential failure and personal injury due to blocked rotation.
Innovation Solution
The absorption device features curved external plates with upper parts folded over the crossmember ends, secured by weld beads spaced from the front face, reducing stress on welds and allowing component rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the upper part of the external plate is welded at the edge near the front face, then the structural strength is improved, but the weld bead stress increases significantly during impact
Solution Approach 1:
The weld bead is repositioned from the front face edge (original position) to the upper face, spaced away from the front face. This spatial relocation in a different dimension reduces the stress concentration on the weld bead during impact while maintaining the structural strength provided by the folded upper part.
2Shape
If the upper part of the external plate extends vertically, then the curvature of the crossmember is increased, but the rotation of impacted components is blocked
Solution Approach 1:
The folded upper part of the external plate creates a dynamic configuration that allows impacted components to rotate towards the energy absorbers during collision. The folding geometry provides a pathway for rotation while maintaining the curvature enhancement benefit.
3Strength
If the weld bead is positioned at the interface edge, then the attachment strength is maximized, but the stress during impact causes tear failure
Solution Approach 1:
The weld bead is relocated from the vulnerable edge interface (front face and upper face intersection) to a position on the upper face spaced from the front face. This dimensional relocation reduces the stress concentration factor during impact while preserving attachment strength through the folded configuration.
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 minimizes weld bead detachment and ensures proper function of external plates, preventing component destruction and personal injury by enabling rotation, thus enhancing impact absorption efficiency.
Implementation Method 1
each including an edge secured to this upper face by at least one weld bead
Implementation Method 2
there is a very low probability of tearing of each associated weld bead and therefore an almost certain guarantee that this external plate will perform its function correctly
Data Source
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AI summary
An absorption device (DA) is fitted to a vehicle and comprises a crossmember (TA) comprising opposite ends (E2) to which there are welded curved external plates (PE2) each having an upper part (PS) extending beyond the upper face (FS) of the corresponding end (E2). Each upper part (PS) is bent over the top of the upper face (FS) of the corresponding end (E2) and has an edge (BP) secured to this upper face (FS) by at least one bead of welding (CS) that is spaced away from the front face (FV) of the corresponding end (E2) in order to reduce the stress applied to it in the event of an impact.