Profiled Beam Clinching Reinforcement for Chassis Weight
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Solution Overview
Problem
Commercial vehicle chassis designs face challenges in achieving optimal performance with minimal weight while ensuring sufficient strength and resilience under varying loads, particularly in semi-trailers and trailers, where existing solutions fail to efficiently distribute loads and attach components without excessive weight or complexity.
Innovation Solution
The solution involves strategically attaching reinforcement plates to profiled beams using the clinching connection technique, which allows for localized reinforcement of the beams in high-load areas, enabling the use of thinner materials and minimizing weight while maintaining structural integrity, and providing a large contact surface for attaching components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the profiled beam is designed with minimal wall thickness to reduce weight, then the weight is reduced, but the strength and resilience under high loads are insufficient
Solution Approach 1:
The patent applies local quality by differentiating the wall thickness of the profiled beam into two distinct zones: a first zone with minimal wall thickness for weight reduction and a second zone with enhanced wall thickness for strength. This localized variation in material distribution allows the beam to achieve both lightweight design and high strength where needed, resolving the contradiction between weight reduction and strength requirements.
2Strength
If reinforcement plates are attached to the entire profiled beam to ensure sufficient strength, then the strength is improved, but the weight is increased and the attachment surface area is reduced
Solution Approach 1:
The reinforcement plate is strategically positioned only in the second zone of the profiled beam where enhanced strength is required, rather than covering the entire beam. This localized reinforcement approach provides the necessary strength in high-load sections while minimizing the additional weight and preserving attachment surface area in other regions.
Solution Approach 2:
The profiled beam is segmented into two distinct zones with different wall thickness characteristics, allowing the reinforcement plate to be applied only to the specific segment (second zone) that requires enhanced strength. This segmentation enables targeted reinforcement that balances strength improvement with weight minimization.
3Weight of moving object
If the profiled beam is designed with minimal wall thickness, then the weight is reduced, but the attachment surface area for add-on parts is insufficient
Solution Approach 1:
The patent creates a local quality distinction where the first zone has minimal wall thickness for weight reduction, while the second zone has enhanced wall thickness that provides sufficient attachment surface area for add-on parts. This localized enhancement ensures that attachment requirements are met in critical areas without increasing the weight of the entire beam structure.
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 a commercial vehicle chassis with reduced weight, improved resilience, and enhanced attachment capabilities, achieving weight savings of at least 15% and maintaining corrosion protection without additional measures, while ensuring the clinched joints have higher strength and fatigue resistance than traditional spot welds.
Implementation Method 1
a section of the reinforcement plate or profile beam corresponding to the pressure surface of the punch is pressed into the die with plastic deformation, similar to deep drawing
Data Source
Figure 1
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AI summary
The present invention relates to a profiled beam for a vehicle chassis, wherein a reinforcement plate (5, 6, 7) bears against at least one part (T1 - T3) of the profiled beam (1, 20), which reinforcement plate is connected fixedly and non-detachably to the associated part (T1 - T3) of the profiled beam (1, 20). The profiled beam (1, 20) according to the invention for a vehicle chassis, and a utility vehicle chassis constructed using a profiled beam of said type, can be produced inexpensively and have optimal usage characteristics while being of minimal weight. This is achieved in that the connection between the reinforcement plate (5, 6, 7, 22) and the associated part (T1, T2, T3) of the profiled beam (1, 20) is produced by means of at least one clinched connection (D1 - D4).