Multi-Strip Bumper Beam Assembly for Flexible Cross-Section Design
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Solution Overview
Problem
Current methods for manufacturing automotive bumper reinforcement beams face challenges in achieving high dimensional consistency, reliability, and design flexibility while minimizing weight, cost, and capital investment, particularly due to limitations in roll forming and extrusion processes.
Innovation Solution
The use of multiple elongated metal sheets with preformed structures, welded together to form tubular beams with non-linear lengths and varying cross-sections, including non-radiused perpendicular corners, allows for optimized wall thickness and shape distribution, and employs low heat-affect-zone welding processes to enhance impact strength and reduce material costs.
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 that are formed individually and then joined together. Each sheet can be independently formed with different cross-sectional shapes, thicknesses, and material properties, allowing design flexibility while maintaining efficient roll forming processes for each component
Solution Approach 2:
The invention uses composite construction by joining multiple sheets together to form the final beam structure. This allows different sheets to be made from different materials or have different material properties, enabling optimized performance and design flexibility that cannot be achieved with single-sheet roll forming
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 are joined together, allowing each sheet to be optimized for specific functions. This eliminates the need for secondary operations like curving and hole-punching on the final assembled beam, as these features can be incorporated during the individual sheet forming process
Solution Approach 2:
Features such as curves, holes, and other secondary operations are performed on individual sheets before they are joined together. This preliminary action eliminates the need for subsequent secondary operations on the completed beam, reducing manufacturing complexity and cost
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:
By dividing the beam into multiple separately-formed sheets that are then joined, each sheet can be precisely formed using roll forming or other high-precision processes. The modular nature of this approach maintains dimensional consistency while allowing design flexibility in the overall beam configuration
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
This approach results in beams with improved impact resistance, reduced weight, and cost-effectiveness, enabling the production of beams with higher strength-to-weight ratios using a wider range of materials, including stronger aluminum grades, while minimizing secondary processing and capital expenditures.
Implementation Method 1
welded together to form tubular beams with non-linear lengths and varying cross-sections
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.