Parallel Laser Welding for Vehicle Door Frame Stiffness
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Solution Overview
Problem
In vehicle door construction, achieving high frame stiffness while minimizing component costs and weight is challenging due to the need for increased material thickness in sheet metal parts.
Innovation Solution
A component arrangement using a laser welding connection with two parallel welding seams that extend over a predetermined length, configured as stitch-welding seams with alternating segments and gaps to reduce heat input and prevent warping, enhancing stiffness without increasing material thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the sheet metal thickness is increased to achieve high frame stiffness, then the frame stiffness is improved, but the component weight and material costs increase
Solution Approach 1:
The laser welding connection is divided into at least two parallel welding seams instead of a single continuous weld. This segmentation distributes the heat input across multiple separate zones, reducing localized thermal effects and distortion while maintaining overall connection stiffness. The welding seams are arranged parallel to each other and extend over a defined weld seam length, creating a segmented reinforcement structure that achieves high stiffness without increasing material thickness.
2Strength
If the sheet metal thickness is increased to achieve high frame stiffness, then the frame stiffness is improved, but the material costs increase
Solution Approach 1:
The laser welding connection is divided into at least two parallel welding seams instead of a single continuous weld. This segmentation distributes the heat input across multiple separate zones, reducing localized thermal effects and distortion while maintaining overall connection stiffness. The welding seams are arranged parallel to each other and extend over a defined weld seam length, creating a segmented reinforcement structure that achieves high stiffness without increasing material thickness.
3Strength
If continuous laser welding is used to ensure rigid connection, then the connection strength is improved, but component warping increases due to localized heat input
Solution Approach 1:
The laser welding connection is divided into at least two parallel welding seams instead of a single continuous weld. This segmentation distributes the heat input across multiple separate zones, reducing localized thermal effects and distortion while maintaining overall connection stiffness. The welding seams are arranged parallel to each other and extend over a defined weld seam length, creating a segmented reinforcement structure that achieves high stiffness without increasing material thickness.
Solution Approach 2:
The welding process is applied periodically through stitch-welding seams consisting of individual seam segments spaced apart by gaps. This periodic action allows heat to dissipate between welding pulses, preventing excessive localized heat accumulation that would cause warping. The seam segments are arranged in alternating succession with longitudinal offsets, creating a periodic welding pattern that maintains connection strength while controlling thermal distortion.
4Shape
If stitch-welding seams with alternating segments are used to reduce heat input, then warping is reduced, but the welding process complexity increases
Solution Approach 1:
The welding process is applied periodically through stitch-welding seams consisting of individual seam segments spaced apart by gaps. This periodic action allows heat to dissipate between welding pulses, preventing excessive localized heat accumulation that would cause warping. The seam segments are arranged in alternating succession with longitudinal offsets, creating a periodic welding pattern that maintains connection strength while controlling thermal distortion.
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 configuration significantly increases the stiffness of the connection, reduces material costs, and minimizes warping risks, creating a warp-resistant, band-shaped stiffening structure for vehicle door frames.
Implementation Method 1
the first and second profile parts are connected to each other at the respective flanges via a laser welding connection, which extends over a welding seam length
Implementation Method 2
this subjects the two border flanges of the components to a significant localized heat input in the lap joint region, which may result in warping of the components
Data Source
AI summary
A component arrangement includes a first sheet metal profile part and a second sheet metal profile, each first and second profile parts having respective flanges and being arranged relative to each other so that the respective flanges overlap, wherein the first and second profile parts are connected to each at the respective flanges via a laser welding connection, which extends over a welding seam length, wherein the laser welding connection is formed by at least two welding seams which extend parallel and at a distance to each other.