Door Frame Through-Hole Welding Single-Side Access
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Solution Overview
Problem
The existing door frame manufacturing process requires welding devices on both the inside and outside of a vehicle, increasing manufacturing costs due to the need for movable welding mechanisms and equipment.
Innovation Solution
A door frame design featuring through-holes in the door-frame components allows for welding from a single side, reducing the need for multiple welding devices and equipment by forming weld beads between the through-holes and the sash body, thereby simplifying the welding process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is performed from both the inside and outside of the vehicle to attach the door-frame component to the sash body, then welding strength is improved, but manufacturing cost increases due to requiring multiple welding devices and complex equipment setups
Solution Approach 1:
The invention introduces a through-hole in the door-frame component, transforming the welding approach from surface-level welding on both sides to penetrating welding through a hole. This dimensional change allows the welding torch to access the joint from the inside of the vehicle only, eliminating the need for external welding equipment while maintaining strong weld beads that pass through the component thickness.
Solution Approach 2:
The invention extracts the welding operation from the external side of the vehicle by creating a through-hole pathway. This removes the requirement for welding devices positioned outside the vehicle, isolating the welding process to the internal side only, thereby simplifying equipment requirements and reducing manufacturing cost.
2Reliability
If welding devices are placed on both the inside and outside of the vehicle, then complete welding coverage is achieved, but device complexity and equipment requirements increase
Solution Approach 1:
By creating a through-hole in the door-frame component, the invention changes the welding geometry from external surface welding to internal through-hole welding. This allows complete welding coverage to be achieved from the inside of the vehicle alone, as the welding torch can pass through the hole and create weld beads on both the inner and outer surfaces of the component without requiring external equipment.
3Adaptability or versatility
If a movable welding mechanism is used to access both sides of the vehicle, then welding flexibility is improved, but manufacturing cost and productivity decrease due to increased equipment complexity
Solution Approach 1:
The invention extracts the welding operation from the external environment and relocates it entirely to the internal side of the vehicle by utilizing a through-hole in the door-frame component. This eliminates the need for movable welding mechanisms that would need to traverse the vehicle exterior, allowing the welding torch to remain stationary or move minimally within the vehicle interior, thereby improving manufacturing efficiency and productivity.
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 approach reduces manufacturing costs by enabling welding from a single side of the vehicle, improving welding strength and eliminating the need for complex equipment setups, while maintaining the structural integrity of the door frame.
Implementation Method 1
the door-frame component is attached by welding to the sash body, and wherein weld beads are formed between the wall surfaces of the through-hole for welding and the sash body
Data Source
AI summary
The problem to be solved is to provide a door frame and a method of manufacturing the same, with reducing manufacturing cost. A door frame has a rear sash (vertical sash) (41) for supporting door glass and has a lock-device mounting bracket (door-frame component) (70) attached by welding to the rear sash (41) and having formed therein through-holes (70e, 70d) for welding. Weld beads (73, 75) are formed between the rear sash (41) and the wall surfaces of the through-holes (70e, 70d) for welding, the through-holes (70e, 70d) being formed in the lock-device mounting bracket (70).