Hydroformed Fender-Support Tubes for Vehicle Front-End
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Solution Overview
Problem
Existing vehicle front-end structures require multiple joints and additional components to connect fender-support tubes, increasing cost and assembly time, while lacking efficient load management and complex geometry integration.
Innovation Solution
A vehicle front-end structure featuring a pair of one-piece hydroformed fender-support tubes connected by a single joint in the central region, allowing direct attachment and reducing the need for additional components, with forwardly and transversely extending portions that can be hydroformed to create complex geometries for enhanced load transfer and structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple joints and additional components are used to connect fender-support tubes, then connection reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple separate components (fender-support tubes, cross-member, and joints) into a single integrated hydroformed tube structure. The tube includes forwardly extending portions attached to hinge pillars and transverse portions that connect to each other, eliminating the need for separate cross-members and multiple joints while maintaining structural integrity and load management capabilities.
Solution Approach 2:
The integrated tube is formed using hydroforming technology that allows complex geometries to be created in a single piece. The tube is segmented into functional portions (forwardly extending and transverse portions) that are integrated into one component, reducing assembly complexity while maintaining the load path separation needed for effective load management.
2Strength
If multiple joints and additional components are used to connect fender-support tubes, then structural support is improved, but assembly time and manufacturing cost increase
Solution Approach 1:
The patent combines multiple structural components into a single hydroformed tube that provides all necessary structural support functions. The integrated structure eliminates the need for assembling multiple separate parts, significantly reducing assembly time while maintaining the structural support capabilities through the monolithic construction.
Solution Approach 2:
The complex tube geometry is pre-formed using hydroforming technology before assembly. The forwardly extending and transverse portions are integrated into the final shape during the forming process, eliminating the need for field assembly of multiple components and reducing assembly time while ensuring structural integrity.
3Ease of manufacture
If traditional joining methods are used for fender-support tubes, then manufacturing process is simple, but load management efficiency is reduced
Solution Approach 1:
The patent employs hydroforming technology that uses high pressure fluid to plastically deform metal sheets into complex three-dimensional tube shapes. This process parameter change (from conventional forming to hydroforming) enables the creation of integrated complex geometries that optimize load paths while maintaining manufacturing efficiency through a single-step forming process.
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
This solution simplifies the assembly process, reduces costs, and enhances load management by enabling direct connection of tubes with complex geometries, improving the structural integrity and performance of the vehicle front-end.
Implementation Method 1
a pair of one-piece hydroformed tubes
Data Source
AI summary
A vehicle includes a frame and a body supported above the frame. The body includes a pair of hinge pillars disposed on opposite sides of the body and a bulkhead extending between the hinge pillars. A pair of one-piece hydroformed front-support tubes is each attached to one of the hinge pillars at a back end of the tube. Each of the tubes includes a forwardly extending portion, and a transversely extending portion attached to the frame and terminating at a front end. The front ends are attached to each other by an overlapping joint located behind a front fascia of the vehicle.