Extruded Vehicle Chassis Central Pillar Interlocking Design
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Solution Overview
Problem
Current chassis manufacturing methods are complex and costly when using aluminum or producing small series vehicles with a low number of parts, as they require multiple welded parts and complex construction processes.
Innovation Solution
A vehicle chassis design featuring a central body made of aluminum with extruded linear bars joined by welding at structural nodes, and monolithic central pillars inserted and welded into door sills, providing high mechanical strength and low weight through a one-piece extrusion and interlocking mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple pressed parts are superimposed and welded to form central pillars, then the chassis can be manufactured quickly and cost-effectively for mass production, but the construction becomes complex and costly when using aluminum material or producing small series vehicles
Solution Approach 1:
The patent merges multiple separate pressed parts into a single monolithic central pillar made by extrusion. This eliminates the need for superimposing and welding multiple parts, thereby reducing construction complexity while maintaining manufacturing efficiency. The single-piece extrusion design directly addresses the contradiction by combining structural integrity with simplified assembly.
Solution Approach 2:
The patent segments the chassis construction into modular components where central pillars are produced as separate extruded elements that can be independently manufactured and then assembled. This segmentation allows for specialized extrusion processes for each pillar while simplifying the overall assembly process, resolving the contradiction between manufacturing efficiency and construction complexity.
2Ease of manufacture
If multiple pressed parts are welded together to form central pillars, then mass production is cost-effective, but the process becomes more complex and costly for small series automobiles
Solution Approach 1:
The patent combines multiple welded pressed parts into a single monolithic extrusion, eliminating welding operations and associated complexities. This merging approach maintains cost-effectiveness by reducing the number of manufacturing steps and materials required, while specifically benefiting small series production by eliminating setup and tooling requirements for multiple separate parts.
Solution Approach 2:
The patent changes the manufacturing parameter from assembling multiple pressed parts through welding to producing a single extruded component. This parameter change in the manufacturing process fundamentally simplifies construction while maintaining cost-effectiveness across different production volumes, including small series automobiles.
3Strength
If a monolithic extruded central pillar is used, then the chassis achieves high mechanical strength and low weight, but the manufacturing process becomes more suitable for small series rather than mass production
Solution Approach 1:
The patent merges multiple structural components into a single monolithic extrusion, which inherently provides superior mechanical strength due to continuous grain structure and elimination of weld joints. The merging also reduces overall weight by eliminating redundant material at joints and connections, directly achieving the strength and weight benefits while the extrusion process itself can be scaled for different production volumes.
Solution Approach 2:
The patent utilizes extruded aluminum or aluminum alloys as the material for central pillars, combining the benefits of high strength-to-weight ratio with the advantages of extrusion manufacturing. This material selection enables both high mechanical strength and adaptability to different production scales, as extrusion can be efficiently performed for both small batches and mass production.
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
The design results in a robust, cost-effective, and lightweight chassis suitable for small series vehicles, with simplified manufacturing and enhanced mechanical strength, especially in side collision scenarios.
Implementation Method 1
extruded linear bars, which are joined together by welding at structural nodes
Implementation Method 2
each having a through hole; and a pair of central pillars, each of which raises perpendicularly and vertically from a door sill, is made in one piece, is inserted in an interlocking way in the through hole of a window sill
Implementation Method 3
is welded to the window sill at the through hole
Data Source
Figure 1
Figure 2~4
AI summary
A chassis (1) of a vehicle; the chassis (1) is provided with a pair of door sills (5) arranged longitudinally under the door zone and each having a through hole (7); and a pair of central pillars (6), each of which raises perpendicularly and vertically from a door sill (5), is made of one piece, is inserted in an interlocking way in the through hole (7) of a window sill (5) and is welded to the window sill (5) at the through hole (7).