Engine Cradle Fixation Structure for Lighter, Flexible Manufacturing
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Solution Overview
Problem
The existing engine cradle support devices face limitations in terms of complexity, cost, material choice, and adaptability due to the need for metal molding, which restricts design freedom and mechanical characteristics, particularly in weight reduction and environmental adaptation.
Innovation Solution
The support device is designed with a fixation device comprising two distinct parts - a fixation part and a base part, allowing for separate production and assembly, enabling greater flexibility in material choice, shape design, and manufacturing processes, including the use of steel, while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the fixation device is produced as one integral part by metal molding, then the shape complexity and structural integrity are improved, but the manufacturing cost, weight, and design flexibility deteriorate
Solution Approach 1:
The fixation device is divided into two separate parts: a base part and a fixation part. The base part can be produced by stamping or bending processes, while the fixation part is produced separately and then assembled to the base part. This segmentation allows each part to be optimized independently for weight and manufacturing efficiency while maintaining the overall structural integrity of the complete fixation device.
2Strength
If metal molding is used to produce the fixation device, then the structural integrity is improved, but the manufacturing productivity and adaptability deteriorate
Solution Approach 1:
The fixation device is segmented into a base part and a fixation part that can be manufactured using high-productivity stamping and bending processes respectively, then assembled together. This eliminates the low-productivity metal molding process while maintaining structural integrity through the assembled connection of the two parts.
Solution Approach 2:
The base part and fixation part are produced separately in advance using efficient stamping and bending processes, then pre-assembled into the complete fixation device before installation. This preliminary production of components using high-productivity processes significantly improves manufacturing productivity compared to traditional metal molding.
3Strength
If the fixation device is produced as one integral part by metal molding, then the structural integrity is improved, but the material choice and design flexibility deteriorate
Solution Approach 1:
The fixation device is divided into separate base part and fixation part components, each of which can be manufactured from different materials and designed independently. This segmentation provides flexibility in material selection (e.g., steel, aluminum, plastics) and design adaptation for different applications while maintaining the structural integrity of the assembled device.
4Adaptability or versatility
If the fixation horn has a complex shape to accommodate multiple functions, then the functional integration is improved, but the manufacturing complexity and cost deteriorate
Solution Approach 1:
The complex fixation device is segmented into a base part (produced by stamping) and a fixation part (produced by bending), each with simpler individual geometries that are easier to manufacture. The functional integration is maintained through the assembly of these simpler components, reducing manufacturing complexity and cost compared to producing the entire complex shape in one piece.
Solution Approach 2:
The base part and fixation part, each produced by simple and efficient processes, are merged through assembly to create the complete fixation device with multiple functions. This merging of separately manufactured components achieves functional integration while avoiding the manufacturing complexity of producing the entire complex shape in a single operation.
Data Source
AI summary
A support device (1) of an engine support structure (2) of a motor vehicle includes at least a support part (4), comprising an upper face (10) and a lower face (12) defining between them a hollow volume (14), and at least one fixation device (8) intended to attach the support part to a vehicle body. The fixation device (8) comprises a fixation part (16) and a base part (18) extending at least partially inside the hollow volume (14) of the support part (4), at least a portion of the upper face (10) and at least a portion of the lower face (12) being applied against at least a portion of the base part (18) on either side of said base part (18. The fixation part (16) and the base part (18) are formed of at least two distinct parts attached together.