Cylinder Restraint Unit with Floor-Integrated Support Structure
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Solution Overview
Problem
Existing solutions for securing high-pressure combustible gas cylinders in motor vehicles require additional support frames that are heavy, space-consuming, and prone to stress concentrations, compromising vehicle capacity, height, and assembly efficiency.
Innovation Solution
A restraining unit utilizing a support structure integrated with the vehicle's floor and lateral walls with slotted holes, where belts form a ring around the cylinder, distributing weight uniformly and eliminating stress concentrations, thereby reducing the need for additional support frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a support frame with belts is used to secure the cylinder, then the cylinder is stably supported, but the vehicle weight increases and boot capacity is reduced
Solution Approach 1:
The support frame is merged with the vehicle floor structure by integrating the frame into the existing floor pan and utilizing the floor as part of the support structure. This eliminates the need for a separate, heavy support frame while maintaining cylinder support stability through the integrated design that distributes loads to the vehicle's existing structural elements.
Solution Approach 2:
The vehicle floor structure serves multiple functions: it acts as both the vehicle floor and part of the cylinder support structure. The floor pan and lateral walls provide both structural support for the vehicle and anchoring points for the belt restraint system, eliminating the need for dedicated support components and reducing overall weight.
2Reliability
If a support frame with screws and nuts is used to secure the cylinder, then the cylinder is firmly restrained, but the device complexity increases and assembly becomes more difficult
Solution Approach 1:
The complex screw and nut fastening system is extracted and replaced with a simplified belt restraint system. The belts are secured using simple cleat-style fasteners that wrap around the cylinder and attach to the lateral walls, eliminating the need for multiple screws, nuts, and tightening mechanisms while maintaining firm restraint through friction and geometric locking.
Solution Approach 2:
Flexible belts replace rigid metal frame components and complex fastening mechanisms. The belts conform to the cylinder shape and provide restraint through tension and friction, while the flexible nature allows for easier installation and adjustment compared to rigid screwed connections.
3Reliability
If a support frame is added to secure the cylinder, then the cylinder is properly supported, but the vehicle height is reduced and space availability is compromised
Solution Approach 1:
The support structure is merged with the vehicle floor, utilizing the existing floor height and structure. The lateral walls extend upward from the floor to provide belt anchoring points, eliminating the need for an additional overhead support frame that would reduce vehicle height and headroom.
Solution Approach 2:
The support structure utilizes the vertical dimension efficiently by having lateral walls extend upward from the floor to provide anchoring points for the belts. This vertical arrangement allows the belts to wrap around the cylinder and attach at different heights, providing adequate support without requiring a heavy overhead frame structure.
4Reliability
If belts with screw fixings are used to restrain the cylinder, then the cylinder is securely held, but stress concentrations occur at the fixing points
Solution Approach 1:
Flexible belts replace rigid metal straps with screw fixings. The belts distribute stress along their length and conform to the cylinder shape, reducing stress concentrations at discrete fixing points. The cleat-style fasteners distribute loads over a larger area compared to point-loaded screws.
Solution Approach 2:
The belts are pre-formed into loops or configured to wrap around the cylinder in a way that distributes loads before final attachment. The cleat fasteners are designed to gradually tighten and distribute stress evenly along the belt-cylinder contact area, preventing stress concentrations that would occur with direct screw-to-belt connections.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A restraining unit (1) for fitting a combustible gas cylinder (2) into a motor vehicle and provided with a support structure (3) which is defined by a floor portion of the motor vehicle and has an intermediate wall (4) defining a seat (5) which houses an upper portion (6) of the cylinder (2); the support structure (3) has, moreover, the two lateral wall portions (8) arranged on opposite lateral sides of the seat (5) and having respective slotted holes (9) through which a restraining belt (16) passes; the restraining belt (16) defines a ring which winds completely round the cylinder (2) by interposition of the intermediate wall (4).