Gusset With Locking Claws For Vehicle Body Superstructure
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Solution Overview
Problem
Conventional vehicle body superstructures face challenges in efficiently reinforcing the joining portions between the roof member and side rail members, which can lead to reduced strength and stiffness, especially during side impacts, and complicate the assembly process.
Innovation Solution
A vehicle body superstructure design featuring a gusset with a rail side surface, a roof side surface, first and second claws, and a bead, where the claws are locked into locking portions of the side rail members and the bead extends from the rail side surface to the roof side surface, enhancing the structural integrity and simplifying the assembly by allowing automatic locking and bolt fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional gusset design is used to reinforce the joining portion between the roof member and side rail members, then the structural strength is improved, but the assembly process becomes complicated and time-consuming
Solution Approach 1:
The gusset is divided into multiple functional segments: a body portion with a roof member attachment portion and side rail member attachment portions, plus separate first and second claws that are bent from the body portion. This segmentation allows each part to perform its specific function independently while simplifying the overall assembly process, as the claws automatically engage with locking portions during installation.
Solution Approach 2:
The claws are pre-formed as integral parts of the gusset body portion, positioned and shaped in advance to automatically engage with the locking portions of the side rail members during assembly. This preliminary preparation eliminates the need for manual intervention or complex fastening operations during the assembly process, thereby reducing assembly complexity and time.
2Manufacturing precision
If manual intervention is required during gusset assembly, then positioning accuracy is improved, but productivity decreases
Solution Approach 1:
The gusset is designed to perform its own positioning and locking functions during assembly. The claws automatically engage with the locking portions of the side rail members when the gusset is installed, and the anti-fall portions prevent downward displacement. This self-servicing mechanism ensures accurate positioning without requiring manual intervention, thereby maintaining manufacturing precision while significantly improving productivity.
3Ease of manufacture
If the gusset structure is simplified to reduce manufacturing cost, then ease of manufacture is improved, but the ability to transmit side impact loads deteriorates
Solution Approach 1:
The gusset design incorporates three-dimensional structural features including vertically extending rail side surfaces, horizontally extending roof side surfaces, and protruding claws that engage in multiple directions. The bead extending from the rail side surface to the roof side surface adds dimensional complexity that enhances load transmission capability in multiple directions, particularly for side impact loads, while still being manufacturable from a single metal sheet through forming operations.
Solution Approach 2:
The gusset utilizes the inherent properties of metal sheets through strategic forming and shaping to create a composite-like structure with enhanced mechanical properties. The combination of the body portion, rail side surfaces, roof side surfaces, claws, and bead creates a integrated structure that distributes and transmits side impact loads effectively throughout the vehicle body superstructure, achieving high strength without requiring multiple separate components or complex materials.
Data Source
AI summary
A vehicle body superstructure includes a first side rail member, a second side rail member, a roof member, and a gusset. The gusset includes a rail side surface, a roof side surface, a first claw, a second claw, and a bead. The rail side surface extends along a vertical direction of a vehicle body and is connected to the first and second side rail members. The roof side surface extends along a breadthways direction of the vehicle body and is connected to the roof member. The first claw is provided at a first longitudinal end of the gusset and locked in a first locking portion provided in the first side rail member. The second claw is provided at a second longitudinal end of the gusset and is locked in a second locking portion provided in the second side rail member.