Curved-Flange Support Beam for High Rigidity per Mass
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Solution Overview
Problem
Existing support beams in vehicles lack sufficient rigidity per mass, leading to deformation under bending loads and interference with surrounding components, which affects running stability and durability.
Innovation Solution
A support beam design featuring a web and flange configuration with bent portions, where the flange's centerline is bent outward in the extending direction of the web, increasing the area moment of inertia in both the vehicle height and width directions, enhancing rigidity while reducing weight and compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the rigidity of the support beam is increased by conventional means, then the deformation under bending load is suppressed, but the weight and size of the support beam increase
Solution Approach 1:
The flange includes a bent portion at which the center line of the thickness is bent outward in the extending direction of the web. This curvature in the flange structure increases the area moment of inertia, thereby enhancing rigidity without requiring additional material or increased cross-sectional dimensions, effectively resolving the contradiction between rigidity and weight
Solution Approach 2:
The invention changes the geometric parameters of the arm cross-section by introducing a bent portion in the flange. This modifies the distribution of material in the cross-section to maximize the area moment of inertia, achieving higher rigidity per unit mass through optimized geometry rather than simply increasing material quantity
2Strength
If the rigidity of the support beam is increased by conventional means, then the deformation under bending load is suppressed, but the support beam becomes larger and interferes with surrounding components
Solution Approach 1:
The bent portion in the flange creates a curved geometry that efficiently distributes stress and increases the area moment of inertia within the existing spatial envelope. This allows the support beam to achieve higher rigidity without expanding its external dimensions, preventing interference with surrounding components
Solution Approach 2:
The bent portion utilizes the thickness dimension of the flange more effectively by curving the center line of the thickness outward. This three-dimensional geometric modification increases the area moment of inertia without increasing the planar dimensions of the support beam, maintaining compactness while enhancing rigidity
3Strength
If the area moment of inertia is increased to enhance rigidity, then the bending load resistance is improved, but the manufacturing complexity increases
Solution Approach 1:
The bent portion in the flange is defined by specific geometric parameters (bending radius, bend location, angle) that can be directly incorporated into manufacturing specifications. This parameter-based design allows for precise control of the area moment of inertia while maintaining manufacturability through standard forming or machining operations
Data Source
AI summary
A support beam includes a first supporting portion, a second supporting portion, and an arm connecting the first supporting portion to the second supporting portion. The arm includes a web and a flange. The flange includes a first end, a second end, and a center portion. The center portion of the flange is connected to an end of the web. The flange includes bent portions at which the center line of the thickness of the flange is bent outward in the extending direction of the web in the region between the first end and the second end in a transverse cross section of the arm.