Modular Stiffening Modules for Sheet Element Weight Reduction
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Solution Overview
Problem
Existing methods for stiffening sheet elements in lightweight construction often result in oversizing, leading to unnecessary material consumption and increased weight, which in turn increases energy requirements and CO2 emissions.
Innovation Solution
A method involving the use of stiffening modules with a flange and at least one web, attached sequentially along a load path determined by stress-optimized calculations, forming a non-rectilinear stiffening structure that can be manufactured using conventional processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If linear profiles are used for stiffening structures, then ease of manufacture is improved, but weight of the construction increases
Solution Approach 1:
The stiffening structure is divided into multiple individual stiffening elements that are arranged sequentially along the load path. Each element can be manufactured separately using conventional processes and then assembled, allowing for weight optimization while maintaining ease of manufacture through modular construction.
Solution Approach 2:
The cross-sectional properties of the stiffening elements are varied along the load path according to the local stress requirements. Elements are designed with different dimensions and shapes at different locations, allowing material to be placed only where needed, thus reducing overall weight while maintaining structural integrity.
2Strength
If stiffening structures are oversized for local maximum stress, then strength is improved, but weight of the construction increases
Solution Approach 1:
Each stiffening element is designed with cross-sectional properties specifically optimized for the local maximum stress conditions at its position along the load path. This ensures that each element has sufficient strength for its specific location without being oversized for other areas, minimizing overall weight.
Solution Approach 2:
The load path and stress distribution are determined through preliminary stress-optimized calculations and simulations before manufacturing the stiffening elements. This allows the elements to be precisely sized for their specific locations, avoiding oversizing while ensuring adequate strength.
3Weight of stationary object
If topology-optimized non-rectilinear load paths are implemented, then weight of construction is reduced, but device complexity increases
Solution Approach 1:
The complex topology-optimized load path is segmented into a sequence of individual stiffening elements with relatively simple geometries. Each element maintains a simple cross-section that can be manufactured conventionally, while the overall non-rectilinear arrangement follows the optimized load path, achieving weight reduction without excessive manufacturing complexity.
4Ease of manufacture
If conventional manufacturing methods are used for bionic structures, then ease of manufacture is improved, but manufacturing precision decreases
Solution Approach 1:
The structure is divided into discrete stiffening elements that can be manufactured using conventional methods with standard tolerances. The modular nature allows each element to be produced independently with conventional precision, and the overall structural precision is achieved through the systematic arrangement and connection of these elements rather than requiring high precision in each individual component.
Data Source
AI summary
A method for stiffening a sheet element is provided. In this regard, the method preferably includes a first step of providing stiffening modules that have a flange and at least one web. Furthermore, the stiffening modules are preferably attached to the sheet element sequentially along a load path, the stiffening modules are connected to each other via their respective flanges using connecting means and/or joining methods for a positive, frictional and/or materially bonded connection to form a stiffening structure, such that the stiffening modules have a combined effect, specifically stiffening and reinforcing the sheet element. A stiffening structure for a sheet element is also provided that includes stiffening modules arranged sequentially, and to a stiffening system including a stiffening structure and a sheet element.