Rear Cross Member Integrated Structure Reduces Weld Cracks
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Solution Overview
Problem
The existing rear cross member for vehicles is complex and prone to cracks in the weld zones due to separate components joined by welding, leading to assembly complications and reduced durability under load.
Innovation Solution
A rear cross member design featuring an integrated structure with an upper plate, lower plate, and front panel, where the upper and lower side parts are formed to extend and couple, and bosses are press-fitted to absorb shocks, reducing the number of coupling components and improving assembly efficiency and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate components are joined by welding, then assembly is possible, but the structure becomes complicated and cracks occur in weld zones under load
Solution Approach 1:
The patent merges multiple separate components (front panel, rear panel, side members) into an integrated rear cross member structure. The upper and lower plates are formed as single integral pieces with side parts extending therefrom, eliminating the need for separate welding operations between these components and simplifying the overall structure while maintaining assembly capability through the integrated design
2Ease of manufacture
If separate components are joined by welding, then assembly is possible, but cracks occur in weld zones when load is applied
Solution Approach 1:
The patent eliminates weld zones by integrating components into a unified structure where the upper and lower plates are formed as single pieces with side parts. This merging removes the weak weld zones that are prone to cracking under load, thereby improving reliability and durability while still enabling assembly through the integrated design
3Adaptability or versatility
If multiple separate components are used, then functionality is achieved, but assembly process is complicated and productivity is reduced
Solution Approach 1:
The patent combines multiple functional components into an integrated rear cross member where the upper plate, lower plate, and side members form a unified structure. This merging maintains all necessary functional capabilities while significantly simplifying the assembly process and improving productivity by reducing the number of separate parts and assembly operations required
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
The integrated structure simplifies the assembly process, enhances productivity, and improves durability by reducing the complexity of weld zones and enhancing the coupling force between components, effectively absorbing external shocks.
Implementation Method 1
an absorber that is interposed between the central shaft and the outer support and absorbs shocks transmitted from the central shaft or the outer support
Data Source
AI summary
A rear cross member for a vehicle includes: an upper plate including an upper body, and upper side parts that are formed to extend from opposite ends of the upper body; a lower plate including a lower body that is coupled with the upper body, and lower side parts that are formed to extend from opposite ends of the lower body and are coupled with the upper side parts; and a front panel connected to the upper and lower plates.