Integrally Formed Cantilever Bracket Eliminates Welding
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Solution Overview
Problem
Existing cantilever mounting devices require significant manufacturing effort, are prone to mechanical stress, and often necessitate costly post-treatment processes, such as galvanizing, which can lead to material defects and reduced load-bearing capacity.
Innovation Solution
A cantilever design featuring a channel-shaped support arm with integrally connected side pieces and a mounting plate, made from inexpensive galvanized sheet metal, which allows for easy assembly and eliminates the need for post-treatment, using a counter plate for additional support and a modular structure for customizable strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to connect the support arm to the mounting part, then the structural strength is improved, but the manufacturing complexity and post-treatment requirements increase significantly
Solution Approach 1:
The support arm and mounting part are merged into a single integrally formed component made from one sheet metal blank. The mounting part is formed by reshaping the end pieces of the support arm through bending and forming operations, eliminating the need for separate welding processes while maintaining structural integrity through continuous material flow and inherent geometric strength.
Solution Approach 2:
The single sheet metal blank is segmented and reshaped into distinct functional zones: the support arm portion and the mounting part portion. These zones are created through forming operations that bend and reshape the material in-place, creating what appears to be separate components while actually maintaining a continuous, weld-free structure.
2Strength
If welding is used to assemble the cantilever, then the load-bearing capacity is improved, but material damage and oxidation risk increase
Solution Approach 1:
By merging the support arm and mounting part into a single integrally formed component, the invention eliminates welding operations that would otherwise damage the galvanized protective layer and create oxidation-prone zones. The continuous metal structure provides inherent load-bearing capacity without requiring thermal joining processes that compromise material integrity.
Solution Approach 2:
The invention converts the potential harm of welding-induced damage to the galvanized layer into a benefit by designing a structure that achieves its load-bearing capacity through integral forming. This approach not only preserves the protective zinc coating but also eliminates the need for costly post-weld galvanizing repairs and oxidation prevention measures.
3Stability of the object's composition
If multiple connection points are used to join the head part to the support arm, then the structural stability is improved, but the manufacturing effort and assembly complexity increase
Solution Approach 1:
The invention merges the head part and support arm into a single integrally formed component, eliminating the need for multiple connection points and fasteners. The continuous material structure provides inherent stability while dramatically simplifying manufacturing to a single-forming operation from one sheet metal blank.
4Reliability
If galvanized sheet metal is used for the support arm, then the corrosion resistance is improved, but the protective layer is damaged during welding requiring expensive post-treatment
Solution Approach 1:
By merging the support arm and mounting part into a single integrally formed component from galvanized sheet metal, the invention preserves the protective zinc coating throughout the entire structure. The forming process maintains the continuous galvanization without creating exposed metal surfaces that would require post-weld galvanizing repairs, eliminating expensive post-treatment operations.
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The boom (1) comprises a U-profile-shaped support arm (11) having a first and a second side section (111, 112) integrally connected to each other by a central section (113), and which is connected at one end to a head section (12) that can be connected to a support (2) by a connecting element (9). According to the invention, the head section (12) comprises end sections (1111, 1121) of the two side sections (111, 112) that are angled relative to each other and overlapping each other, as well as a mounting plate (14) which is connected to the two end sections (1111, 1121) of the two side sections (111, 112) by at least one connecting element (95) and which has a mounting opening (148) for receiving the connecting element (9).