Motorcycle Engine Bracket Forging with Variable Thickness
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Solution Overview
Problem
The existing motorcycle frame assembly process is complex and inefficient due to the need for multiple separate components to be welded, which complicates positioning accuracy and increases production time, while conventional engine brackets struggle to balance strength, stiffness, and flexibility.
Innovation Solution
The motorcycle frame integrates multiple components into unitary pieces, such as gussets and engine mounting brackets, to reduce the number of parts that need to be welded, and uses a forging process to create engine brackets with varying thicknesses to optimize strength, stiffness, and weight, ensuring suitable flexibility and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple separate brackets and gussets are welded to the frame, then positioning accuracy can be maintained, but the assembly process becomes complicated and productivity decreases
Solution Approach 1:
The patent combines multiple separate components (brackets and gussets) into a single integrated frame structure. The frame is designed as one piece with built-in mounting features for the engine, radiator, and other components, eliminating the need for separate welding operations and improving assembly efficiency while maintaining positioning accuracy through precise integrated design
2Strength
If the bracket thickness is increased to provide desired strength, then strength is improved, but weight increases and flexibility is reduced
Solution Approach 1:
The patent applies local quality by varying the thickness of the bracket in different regions. The bracket has a first thickness at the engine mounting portion to provide sufficient strength, and a second thickness at the rear end portion to provide flexibility. This non-uniform thickness distribution allows the bracket to achieve both strength and flexibility without increasing overall weight
3Weight of moving object
If the bracket thickness is decreased to provide flexibility, then weight is reduced, but desired strength is difficult to obtain
Solution Approach 1:
The patent resolves this contradiction by implementing local quality through variable thickness design. The bracket is thinner at the rear end portion to reduce weight and provide flexibility, while being thicker at the engine mounting portion to ensure sufficient strength. This localized thickness adjustment allows the bracket to meet both strength and weight reduction requirements simultaneously
Data Source
AI summary
A frame of a motorcycle includes a head pipe configured to support a steering shaft, a first frame configured to extend from the head pipe, through above and rearward of an engine, and to rearward of a vehicle body, a second frame that is located under the first frame and configured to extend from the head pipe, through forward and downward of the engine, and to rearward of the vehicle body, a bracket by which a first component is mounted to the second frame, and a coupling member that is mounted to the second frame to couple a second component to the second frame, and the bracket is integral with the coupling member. An engine bracket of a motorcycle is manufactured by forging such that a region subjected to tensile stress is made thicker than a region in the vicinity of the region which is subjected to the tensile stress.