Multi-Sheet Box Beam Assembly for Flexible Bumper Cross Sections
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Solution Overview
Problem
Existing bumper reinforcement beams face challenges in achieving high dimensional consistency, flexibility in design, and cost-effectiveness while meeting stringent performance and weight minimization requirements, with limitations in roll forming and extrusion processes.
Innovation Solution
A beam article constructed from multiple elongated metal sheets with non-linear lengths and non-constant transverse cross sections, featuring non-radiused corners and optimized wall thicknesses, welded using low heat-affect-zone processes, allowing for varied wall shapes and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If roll forming process is used to manufacture bumper reinforcement beams, then manufacturing cost is reduced and production efficiency is improved, but the beams are limited to constant cross sectional shapes and single sheet material
Solution Approach 1:
The beam is divided into multiple separate sheets (front wall, rear wall, and one or more intermediate shear walls) that are formed individually using roll forming processes, then assembled together to create the complete tubular beam structure. This allows each sheet to be optimized independently while maintaining the efficiency of roll forming.
Solution Approach 2:
Multiple separately formed sheets are combined through welding to create a unified tubular beam structure. The sheets are positioned to form front and rear walls with intermediate shear walls connecting them, creating a closed-section beam that achieves design flexibility through assembly of standardized components.
2Strength
If extrusion process is used to manufacture aluminum beams, then light weight and high strength-to-weight ratio are achieved, but the beams have constant cross sections and require secondary operations
Solution Approach 1:
The beam structure is segmented into multiple sheets that can be formed with different cross-sectional profiles using roll forming, eliminating the need for extrusion. This allows varied wall thicknesses and shapes in different sections of the beam without requiring secondary operations.
Solution Approach 2:
Different sheets can have different material properties, thicknesses, and formed shapes optimized for their specific locations in the beam structure. The front and rear walls can have different characteristics from the intermediate shear walls, allowing local optimization without the constraints of extrusion processes.
3Adaptability or versatility
If secondary processes are used to reshape roll formed beams, then design flexibility is improved, but manufacturing cost increases and dimensional consistency deteriorates
Solution Approach 1:
The sheets are pre-formed using roll forming processes to achieve their final shapes and dimensions before assembly. The curvature and contouring are built into the sheets during the forming process itself, eliminating the need for subsequent reshaping operations that would compromise dimensional consistency.
Solution Approach 2:
The invention changes the manufacturing parameters by using multiple separately formed sheets with varied thicknesses and profiles that are assembled together, rather than attempting to reshape a single monolithic beam. This allows design flexibility through material and geometric parameter variation while maintaining precision through controlled forming processes.
4Weight of moving object
If aluminum material is used for beams, then weight is reduced and strength-to-weight ratio is improved, but material cost increases
Solution Approach 1:
Different sheets in the beam structure can be made from different materials or different grades of aluminum, allowing optimization of material selection and thickness for each location based on structural requirements. This enables weight reduction in critical areas while using more economical materials in less critical areas.
Solution Approach 2:
The beam can be constructed as a composite structure with sheets of different materials (e.g., aluminum, steel, or other metals) joined together through welding. This allows the structure to achieve the desired strength-to-weight ratio by strategically combining materials with different properties rather than using a single expensive material throughout.
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 provides improved impact resistance, reduced weight, and cost-effectiveness by enabling flexible design and efficient manufacturing, while maintaining high dimensional consistency and meeting industry performance standards.
Implementation Method 1
at least two of the sheets having edges that abut side surfaces of adjacent others of the sheets to form non-radiused perpendicular welded corners
Data Source
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AI summary
A multi-sheet beam includes sheets pre-formed with integral features and to cause a final beam shape with non-radiused corners for optimal impact properties. The beams have constant or varied cross sectional shapes. The sheets are selected to have desired (different) thicknesses and material properties for optimal impact results and low beam weight. To assemble, the sheets are fixtured together and welded to form box beam, such as a two-tube monoleg beam, preferably using welding processes having low heat-affected-zones around the weld. The multiple sheets can include grades of aluminum with high tensile strength well above extrudable grades of aluminum. Alternatively, the multiple sheets can be any grade of steel, such as high strength and ultra-high strength steels. The fixturing and assembly technique minimizes capital expense on extruding machines and/or roll forming machines.