I-Profile Frame Pillar Design for Bus Structural Integrity
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Solution Overview
Problem
Existing frame pillars for large vehicles, such as buses, exhibit low flexural strength with relatively high structural weight, necessitating additional components for support and sealing, which increases weight and manufacturing costs.
Innovation Solution
Designing the frame pillar as an I-profile with an inner and outer contour connected via a central web part, using laser cutting for precise configuration, and incorporating integrated connecting elements and sealing areas to reduce weight and manufacturing costs while enhancing flexural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If framework columns are designed as hollow profiles, then structural weight is reduced, but flexural strength is insufficient
Solution Approach 1:
The framework column is divided into three main segments: inner contour part, outer contour part, and central web part. This segmentation allows each part to be optimized independently for both weight and strength, with the I-profile configuration providing high flexural strength while maintaining low weight
Solution Approach 2:
The framework column uses a composite structure combining multiple sheet metal parts (inner contour part, outer contour part, central web part) that are joined together. This composite approach achieves superior flexural strength-to-weight ratio compared to solid hollow profiles
2Reliability
If additional components are added for support and sealing, then structural integrity is improved, but weight and manufacturing costs increase
Solution Approach 1:
The patent integrates multiple functions into the framework column itself: sealing areas are incorporated into the inner and outer contour parts, and connecting elements are built into the central web part. This eliminates the need for separate support and sealing components, reducing overall weight while maintaining structural integrity
Solution Approach 2:
The framework column is designed as a multi-functional component that simultaneously provides structural support, sealing surfaces, and connection points for transverse and longitudinal supports. This universal design reduces the total number of components needed in the vehicle framework
3Ease of manufacture
If framework columns are designed with fixed contours, then manufacturing is simplified, but design flexibility is limited
Solution Approach 1:
The framework column design allows dynamic adaptation of contours by modifying the inner contour part, outer contour part, and central web part configurations. The laser cutting process enables flexible contour design while maintaining manufacturing efficiency through automated production
Solution Approach 2:
The patent enables contour design flexibility by varying geometric parameters of the I-profile components. Different configurations of the inner contour part, outer contour part, and central web part can be produced by changing cutting patterns and dimensions in the laser cutting 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
The solution achieves increased flexural strength with reduced structural weight, allowing for more flexible contour designs and cost savings through automated production and elimination of unnecessary components, ensuring seamless force flow and improved structural integrity.
Implementation Method 1
the inner contour part and/or the outer contour part and/or the central web part is cut out of a metal sheet by means of a thermal separation process, in particular a laser cutting process
Implementation Method 2
the inner contour part and/or the outer contour part is connected to the central web part by means of a welding process, in particular an elongated hole and/or fillet weld process
Data Source
Figure 1
Figure 2~2b
Figure 3
AI summary
The frame column (24) is designed as I-shape section, and has an internal contour part (26) and an outer contour part (28). The internal contour part and the outer contour part are connected with each other by a centre web part (30). The internal contour part and the outer contour part have a retaining area or a bearing surface for arranging a sealing element, particularly a sealing rubber.