Tubular Dashboard Beam with Flattened Ends
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Solution Overview
Problem
Existing dashboard beams for motor vehicles face challenges in minimizing size and mass while maintaining stiffness and vibration absorption, particularly due to the need for additional reinforcement and precise mounting of stirrups, which can compromise stiffness and increase weight.
Innovation Solution
A one-piece tubular beam with varying diameters, where the ends are partially flattened to integrate the fixing function, allowing for direct attachment to vertical uprights without additional reinforcement, reducing mass and assembly complexity while maintaining sufficient stiffness for vibration absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the beam diameter and thickness are increased to maintain stiffness and vibration absorption, then the stiffness and vibration absorption improve, but the mass increases
Solution Approach 1:
The beam has different diameters at different locations: larger diameter at the ends where stiffness is critical for vibration absorption and mounting, smaller diameter in the central portion where space is limited. This local variation in geometry optimizes the stiffness-to-mass ratio by concentrating material where it is most needed.
2Strength
If additional reinforcement parts are added to maintain stiffness after flattening, then the stiffness is maintained, but the mass and device complexity increase
Solution Approach 1:
The mounting function is integrated directly into the beam structure through flattening the ends, eliminating the need for separate mounting brackets or reinforcement parts. The flattened end itself serves as the mounting surface, combining the structural beam and mounting interface into a single integrated component.
3Device complexity
If the beam ends are flattened to integrate the fixing function, then the device complexity reduces, but the stiffness at the ends is lost
Solution Approach 1:
The beam maintains its circular cross-section at the ends with a diameter large enough to provide sufficient stiffness, while only the outer surface is flattened to create the mounting interface. This localized flattening integrates the mounting function without compromising the overall stiffness of the beam ends.
4Volume of moving object
If the beam diameter is reduced to minimize cockpit space, then the space requirement decreases, but the stiffness and vibration absorption capability are compromised
Solution Approach 1:
The beam has a smaller diameter in the central portion to minimize cockpit space occupation, while the ends maintain a larger diameter to ensure sufficient stiffness and vibration absorption capability. This local variation in diameter optimizes both space utilization and structural performance.
Data Source
Figure 1~3B
Figure 4~6
AI summary
The invention relates to a circular-section tubular dashboard beam (100) designed to extend transversely between the vertical pillars of a motor vehicle. The beam is produced in one piece and has at least two different diameters (d1, d2, dd3) between its two ends, a larger diameter (d1) of the beam being at one end (101, 102) of the beam designed to be located adjacent to a driver's seat of the motor vehicle. According to the invention, at least the end nearest the driver's seat, which must be attached to a vertical pillar of the motor vehicle, is partially flattened, giving it a cross section in the form of an arc of a circle whose cord (105) which closes the section continues on either side of said arc of a circle (106), forming a flat face whose lateral flanges (109) are formed on either side of the arched face of the arc of a circle.