One-Piece Strut-Dome and Engine Support for Faster Vehicle Assembly
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Solution Overview
Problem
Existing load-bearing structural components for motor vehicles face challenges in achieving low weight, high stability, and stiffness while minimizing production time and cost, particularly due to complex manufacturing processes like welding, and lack of reinforcing features in critical transition zones.
Innovation Solution
A one-piece load-bearing structural component is designed with a strut-dome and engine support made from lightweight metal alloys, featuring integrated reinforcing ribs and grooves, and direct mounting points, eliminating the need for welding and separate assembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If separate walls are welded together to form the load-bearing structure, then the structural stability and stiffness are improved, but the production time and manufacturing cost increase
Solution Approach 1:
The patent combines multiple separate walls (front wall, side walls, engine support, strut dome) into a single integrated load-bearing structure produced by stamping and forming operations. This merging eliminates the need for welding separate components together, thereby reducing production time while maintaining structural stability through the integrated design
2Strength
If welding process is used to assemble the load-bearing structure, then the structural strength is improved, but the manufacturing cost increases
Solution Approach 1:
The patent replaces the welding process with stamping and forming operations to create the load-bearing structure. The integrated design allows the structure to be produced as a single piece through metal forming techniques, eliminating welding costs while maintaining structural strength through the inherent properties of the formed metal components
3Productivity
If the load-bearing structure is made as one single piece, then the production time and cost are reduced, but the stiffness in critical areas may be insufficient
Solution Approach 1:
The patent applies local quality by creating specific geometric features (reinforcing ribs, flanges, and formed sections) in critical areas of the integrated load-bearing structure. These localized structural enhancements provide additional stiffness and strength where needed (such as in the engine support and strut dome areas) while maintaining the overall integrated design that reduces production time
4Weight of moving object
If thin wall thickness is used for the strut-dome, then the weight is reduced, but the strength at fixing points is compromised
Solution Approach 1:
The patent applies local quality by creating thicker or reinforced sections at the fixing points of the strut-dome through forming operations. While the general wall thickness remains thin to minimize weight, the localized reinforcement at critical mounting areas ensures sufficient strength for securing the strut and other components
Data Source
Figure 1
Figure 2
AI summary
Load-bearing structural component (1) in particular of a motor vehicle including a strut-dome (2) to hold the strut and an engine support (3) to fasten an engine wherein the load-bearing structural component (1) is formed in one-piece as a single part.