One-Piece Vehicle Bulkhead Forming for Fewer Weld Seams
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Solution Overview
Problem
The manufacturing of modern motor vehicle bulkheads is complex due to the need for numerous individual parts with complex geometries, resulting in a high number of weld seams that require costly corrosion protection treatments.
Innovation Solution
A method involving the forming of two-dimensional metallic semi-finished products to create a one-piece bulkhead that extends over sections of both front wheel arches, using techniques like direct or indirect hot forming and laser welding to reduce the number of parts and simplify assembly, while allowing for varying material properties and openings to adapt to different mechanical stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional methods using numerous individual sheet metal parts are used to manufacture bulkheads, then complex geometries and local reinforcements can be achieved, but the number of weld seams increases and manufacturing cost increases
Solution Approach 1:
The patent merges multiple individual sheet metal parts into a single three-dimensional blank that is formed into a one-piece bulkhead. This combining approach eliminates the need for numerous separate components and their associated weld seams, directly resolving the contradiction between achieving complex geometries and reducing device complexity.
Solution Approach 2:
The patent transitions from assembling two-dimensional sheet metal parts in three-dimensional space to forming a single three-dimensional blank that is then shaped into the final bulkhead. This dimensionality change allows complex geometries to be achieved through forming processes rather than through assembly of multiple flat parts.
2Strength
If numerous individual parts are assembled to form the bulkhead, then complex shapes and local reinforcements can be achieved, but the number of weld seams increases requiring costly corrosion protection treatments
Solution Approach 1:
By combining all necessary reinforcements into a single integrated three-dimensional blank, the patent eliminates numerous weld seams that would require corrosion protection. The local reinforcements are achieved through the forming process itself rather than through separate welded parts.
Solution Approach 2:
The patent extracts the reinforcement function from separate welded components and integrates it directly into the three-dimensional blank through selective thickening or reinforcement features formed during the blank creation process, eliminating the need for subsequent welding and corrosion protection.
3Shape
If multiple individual parts are used to construct the bulkhead, then complex geometries can be achieved, but manufacturing effort and assembly time increase
Solution Approach 1:
The patent combines multiple manufacturing operations into a single forming process that creates the complex three-dimensional shape directly from a three-dimensional blank, eliminating the need for sequential assembly of multiple parts and significantly improving manufacturing efficiency.
Solution Approach 2:
The patent performs preliminary shaping by creating a three-dimensional blank with pre-formed features before final bulkhead formation. This preliminary action allows complex geometries to be established early in the process, reducing the complexity of subsequent forming operations and improving overall productivity.
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 significantly reduces manufacturing effort and cost by creating a simplified, cost-effective one-piece bulkhead with improved mechanical properties and adaptability to different vehicle types, enabling efficient production with reduced processing time and material savings.
Implementation Method 1
a component (22) with a spatial structure is manufactured by means of forming (20) from a two-dimensional metallic semi-finished product (24)
Implementation Method 2
The metal sheets (28) and/or the reinforcing plates (30) can be connected to one another and/or to the metal sheet (28) in particular by means of laser welding
Data Source
AI summary
A method for the manufacture of a bulkhead of a motor vehicle body and method for the manufacture of bulkheads of motor vehicle bodies of different types of motor vehicles. The front wheel arches of the motor vehicle body are at least partly formed by the bulkhead of the motor vehicle. A component with a spatial structure is manufactured from a two-dimensional metallic semi-finished product by forming, wherein the component forms at least part of the bulkhead. The component manufactured by the forming forms at least a large part of the bulkhead in relation to the area of the projection of the bulkhead in the longitudinal direction of the motor vehicle and extends at least over sections of both front wheel arches of the motor vehicle body.