Hollow Beam Coupling System with Polygonal Extruded Profile
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Solution Overview
Problem
Existing trailer systems for motor vehicles face challenges in effectively absorbing loads while maintaining low production costs, as current designs often compromise between strength and manufacturing efficiency.
Innovation Solution
A hollow beam designed as an extruded profile with a polygonal cross section, featuring longitudinal and transverse sections connected by intermediate support sections, which can be easily manufactured and provides robust attachment points for carrying devices, utilizing a combination of straight and curved sections to enhance strength and simplify production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the hollow beam is designed with complex cross-sections and multiple support sections to improve load absorption, then the strength increases, but the manufacturing complexity and production costs increase
Solution Approach 1:
The hollow beam is divided into multiple functional sections: a first hollow beam section with a first cross-section, a second hollow beam section with a second cross-section, and an intermediate hollow beam section connecting them. This segmentation allows each section to be optimized for specific load conditions while maintaining overall structural integrity and manageable manufacturing complexity.
Solution Approach 2:
Different cross-sectional geometries are applied to different sections of the hollow beam based on local load requirements. The first and second hollow beam sections have different cross-sections optimized for their respective positions, while the intermediate section provides a transition. This local optimization strengthens the beam where needed without unnecessarily complicating the entire structure.
2Strength
If the hollow beam uses multiple different cross-sections along its length to optimize strength distribution, then the load absorption improves, but the manufacturing precision requirements increase
Solution Approach 1:
The hollow beam is segmented into distinct sections with defined cross-sections. The first hollow beam section has a first cross-section, the second hollow beam section has a second cross-section, and the intermediate section connects them. This segmentation makes the manufacturing precision requirements manageable by breaking down the complex geometry into discrete, manufacturable segments rather than requiring continuous variation.
Solution Approach 2:
The intermediate hollow beam section features a curved longitudinal axis that connects the first and second hollow beam sections. This curvature provides a smooth transition between different cross-sectional geometries, distributing stress evenly and simplifying the manufacturing process compared to sharp angular transitions, thereby reducing precision requirements.
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 hollow beam effectively absorbs forces acting on the trailer system, allowing for efficient coupling with carrying devices and easy integration with vehicle body areas, while maintaining relatively low production costs and optimizing strength through its geometric design.
Implementation Method 1
the hollow beam is formed by an extruded profile which has a substantially constant cross section along the longitudinal beam sections and the cross beam section
Data Source
Figure 1
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AI summary
The hollow carrier (12) has a cross beam portion (13) that is provided with lateral longitudinal beam sections. The hollow carrier housing is secured over the longitudinal beam sections at structure regions of a passenger car (1) and is provided with a connection system (16) for a carrying device. The hollow carrier housing is provided with an extruded section along the longitudinal beam sections. The cross beam portion is provided with a cross-section that is represented as polygonal profile.