Fuel Cell Vehicle Fastening Bracket Stress Distribution
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Solution Overview
Problem
Fuel cell vehicle components, particularly bolts, are prone to breakage due to varying traveling environments, leading to structural instability and potential safety issues.
Innovation Solution
A fuel cell vehicle design featuring a system frame with strategically positioned fastening parts, including support brackets, bolts, and pipe nuts, that distribute stress and absorb vibrations, minimizing the risk of bolt fracture by employing a combination of protruding and recessed portions and varying bolt diameters to manage shear and tensile forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fastening methods are used to secure the system frame to side members, then the structure is simple and easy to manufacture, but the bolts are prone to breakage under varying traveling environments
Solution Approach 1:
The fastening structure is divided into multiple functional components: support brackets with protruding portions, recessed portions in side members, and strategically positioned bolts. This segmentation allows each component to handle specific stress types, improving overall reliability while maintaining manufacturing feasibility through modular assembly
Solution Approach 2:
Different regions of the fastening structure have specialized properties: protruding portions concentrate tensile forces, recessed portions distribute shear forces, and bolt positions are optimized for specific loading conditions. This local differentiation prevents uniform stress distribution that leads to bolt breakage
2Reliability
If multiple fastening components are used to prevent bolt breakage, then bolt durability improves, but the manufacturing and assembly process becomes more complex
Solution Approach 1:
The support brackets are pre-formed with protruding portions and recessed portions during manufacturing. This preliminary action ensures proper alignment and stress distribution are built into the structure before assembly, reducing the complexity of the assembly process while maintaining high reliability
Solution Approach 2:
Support brackets serve as intermediary components between the system frame and side members. These mediators absorb and redirect forces, protecting the bolts from direct exposure to extreme stresses while simplifying the overall assembly process through standardized connection interfaces
3Strength
If bolts are positioned to overlap aperture boundaries for stress distribution, then structural integrity improves, but the precision required for assembly increases
Solution Approach 1:
The protruding portions are positioned asymmetrically relative to the aperture boundaries, creating intentional offset zones that distribute stresses away from critical bolt locations. This asymmetric design maintains structural integrity while providing tolerance for manufacturing variations in aperture alignment
Data Source
AI summary
A fuel cell vehicle is provided and includes a system frame on which a fuel cell is mounted and first and second side members extending in a first direction and facing each other in a second direction intersecting the first direction. A first fastening part fastens the system frame to each of the first and second side members. The system frame includes a first aperture formed therein in a horizontal direction. The first fastening part includes a first support bracket, including a second aperture, a first insertion hole, and a first tab portion extending from the first insertion hole in the horizontal direction, and a first bolt, including a first shank portion inserted into the first aperture, the second aperture, and the first insertion hole in the horizontal direction and a first threaded portion engaged with the first tab portion.