Motorcycle Body Frame Rear Down Member Integration
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Solution Overview
Problem
The existing motorcycle body frames face challenges in achieving high strength and productivity due to high stress concentrations around the head pipe, which require careful quality control and increased welding, leading to reduced productivity and potential weight issues.
Innovation Solution
The body frame design integrates a rear down frame member with an arm and gusset as a single component, reducing the number of components and welding points, allowing for improved productivity and weight reduction by forming the head pipe and down frame members separately and joining them, thereby simplifying the assembly and reducing the need for overlapping welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the arm and gusset are separated from the rear down frame member, then the joining quality of the welded portion can be controlled more carefully, but the number of components and welding operations increases, lowering productivity
Solution Approach 1:
The arm and gusset are integrated into the rear down frame member as a single unified component. This merging eliminates the need for separate welding operations to join these parts, thereby improving productivity while maintaining structural integrity through the integrated design
2Strength
If multiple members are joined by welding around the head pipe, then the strength and support of the head pipe can be enhanced, but the number of welding beads increases causing weight increase and reduced productivity
Solution Approach 1:
The arm and gusset are merged into the rear down frame member, eliminating redundant welding beads and overlapping structures. This reduces the total weight of the body frame while maintaining the necessary strength support for the head pipe through the integrated structural design
3Stability of the object's composition
If multiple separate members are used for the down frame, then the structural flexibility and support can be improved, but the number of components increases leading to higher manufacturing cost
Solution Approach 1:
The arm and gusset are combined with the rear down frame member into a single integrated component. This reduces the total number of components in the down frame assembly while maintaining structural flexibility and support capabilities through the unified design that incorporates all necessary functional elements
Data Source
AI summary
A body frame has a head pipe supporting a steering shaft, a main frame extended rearward of a vehicle body from the head pipe, and a down frame extended downward of the vehicle body from the head pipe, wherein the down frame includes a front down frame member forming at least a front portion of the down frame, and a rear down frame member forming at least part of a rear portion of the down frame, which are joined. The rear down frame member integrally has an arm supporting the main frame and a gusset reinforcing a joined portion of the main frame to the head pipe.