EV Rocker Closed-Section Reinforcement for Weld Access and Stiffness
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Solution Overview
Problem
Existing rocker assemblies in electric vehicles face challenges in efficiently assembling closed cross-section reinforcements due to accessibility issues of assembly tools and geometrical tolerances, leading to suboptimal mechanical resistance and increased battery pack damage risk during side impacts.
Innovation Solution
A rocker assembly design with a closed section reinforcement that spans the entire hollow volume, secured at transition zones between rocker components' flanges and horizontal walls, using angles between 90° and 180°, allowing for continuous or semi-continuous assembly with filler wire welding or adhesive bonding, optimizing mechanical resistance and cooperation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a closed cross section reinforcement is designed to occupy the biggest possible space within the hollow volume of the rocker assembly, then the mechanical resistance and stiffness performance are improved, but the accessibility of assembly tools such as weld tools deteriorates
Solution Approach 1:
The reinforcement is divided into multiple segments or sections along its length, with assembly zones positioned at strategic locations (such as near the ends or at intervals) where weld tools can access the joint between reinforcement and rocker. This segmentation allows the reinforcement to maintain its full-length closed cross-section for optimal strength while concentrating assembly operations at accessible locations.
Solution Approach 2:
The design introduces intermediary assembly features such as protrusions, recesses, or pre-positioned welding zones on the reinforcement that facilitate tool access. These intermediary elements act as mediators between the large-scale reinforcement structure and the limited-capability assembly tools, enabling efficient joining without compromising the reinforcement's structural integrity.
2Stability of the object's composition
If a closed cross section reinforcement is designed to occupy the biggest possible space within the hollow volume of the rocker assembly, then the stiffness performance is improved, but the geometrical tolerances needed to secure a good assembly become more difficult to achieve
Solution Approach 1:
The reinforcement design incorporates local quality variations where specific zones have features optimized for assembly (such as enlarged cross-sections, positioning lugs, or tolerance-compensating geometries) while the majority of the reinforcement maintains its optimal closed cross-section for stiffness. This allows the structure to achieve high stiffness overall while having localized areas that are more forgiving of manufacturing tolerances.
Solution Approach 2:
The design employs parameter changes in the reinforcement geometry at assembly zones, such as varying the cross-sectional dimensions, wall thickness, or angular orientations locally to accommodate tolerances. These parameter variations enable easier alignment and secure assembly without compromising the overall stiffness provided by the full-length closed cross-section configuration.
3Ease of manufacture
If the reinforcement is secured to the rocker inner and/or outer only at the front and rear extremities of the assembly, then the assembly process is simplified, but the mechanical efficiency of the rocker assembly deteriorates
Solution Approach 1:
The reinforcement is secured at multiple discrete locations along its length rather than continuously, with segmental welding zones positioned at strategic intervals. This segmented approach maintains simplified assembly procedures while ensuring that the reinforcement is adequately anchored at multiple points to prevent excessive bending between attachment locations during impact events.
Solution Approach 2:
The design incorporates preliminary positioning features such as pre-formed bends, positioning lugs, or pre-positioned welding zones that are built into the reinforcement during its manufacturing process. These preliminary actions facilitate easier subsequent assembly operations while ensuring proper alignment and mechanical cooperation between the reinforcement and rocker components throughout the assembly.
Data Source
AI summary
Reinforced rocker assembly having a closed section reinforcement located in the hollow volume formed between the rocker components, wherein the reinforcement is assembled to a rocker component in the transition zones between an upper horizontal wall and an upper flange of the rocker component and in the transition zones between a lower horizontal wall and a lower flange of the rocker component and wherein in the transition zones, the angles α and β formed between the flange and the branch of the reinforcement extending outwards of the rocker component are between 90° and 180°.