Deep-drawn Bushing for Cost-effective Vehicle Body Mounting
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Solution Overview
Problem
Existing motor vehicle body designs with side members in shell construction face challenges in cost-effectively fastening chassis parts while ensuring torsion-resistant connections for optimal driving dynamics and acoustic properties.
Innovation Solution
A deep-drawn sheet metal socket with a support plate is used, which is preassembled with the bushing and can be spot-welded to the side member, providing a cost-effective and torsion-resistant attachment method, allowing for the use of the same socket across different vehicle types with varying support plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a cold-forged bushing is used, then the connection strength is sufficient, but the manufacturing cost is high and welding requires protective gas atmosphere
Solution Approach 1:
The patent changes the manufacturing method parameter from cold-forging to deep-drawing, and changes the material parameter from bar stock to sheet metal. This allows the bushing to be spot-welded instead of requiring protective gas atmosphere welding, reducing manufacturing cost while maintaining connection reliability through the stiffening support plate
Solution Approach 2:
The patent creates a composite structure by combining the deep-drawn sheet metal bushing with a support plate made of sheet metal. This composite construction compensates for the lower inherent strength of deep-drawn components by adding the stiffening effect of the support plate, achieving reliable connection without high manufacturing cost
2Ease of manufacture
If a deep-drawn sheet metal bushing is used, then manufacturing cost is reduced, but the torsional rigidity of the connection is insufficient
Solution Approach 1:
The patent divides the connection system into two functional parts: the deep-drawn bushing for cost-effective manufacturing and spot-welding, and the separate support plate for providing torsional rigidity. This segmentation allows each component to optimize its specific function without compromise
Solution Approach 2:
The support plate acts as an intermediary element between the bushing and the longitudinal beam. It transfers and distributes loads, providing the necessary torsional rigidity to the connection while allowing the bushing itself to remain a simple, cost-effective deep-drawn component
3Adaptability or versatility
If multiple components are assembled during body-in-white construction, then versatility is achieved, but the assembly complexity and time increase
Solution Approach 1:
The patent merges the bushing and support plate into a pre-assembled unit that is manufactured and tested separately, then installed as a single component during body-in-white construction. This reduces assembly complexity at the final assembly stage while maintaining the versatility of having different support plate configurations available for different vehicle types
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 solution enables a cost-effective, torsion-resistant connection of chassis parts to the vehicle body, enhancing driving dynamics and acoustic performance, while reducing production costs and allowing for versatile application across various vehicle configurations.
Implementation Method 1
it can be spot-welded to the longitudinal beam in sheet metal shell construction
Implementation Method 2
The bushing and the at least one support plate are welded together to form a pre-assembled unit
Data Source
Figure 1~2b
AI summary
In prior art, a chassis part can be screwed to a previously known longitudinal beam of a motor vehicle body. Said longitudinal beam is composed of two sheet metal shells which enclose a hollow space and are connected to each other by means of two flanges. An internally threaded bush which protrudes into the hollow space is welded to one of the sheet metal shells, thus allowing the chassis part to be screwed to the longitudinal beam. The aim of the invention is to design a motor vehicle body comprising a longitudinal beam on which a chassis part can be mounted at a low cost. According to the invention, the bush (3, 3') is a deep-drawn sheet metal component. Deep-drawn sheet metal components can be produced at a very low cost. A deep-drawn bush (3, 3') is significantly less expensive than a cold forged bush known in prior art.