Sheet Aluminum Ramp Structure Without Extruded Components
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Solution Overview
Problem
The importation of extruded aluminum components for vehicle loading ramps has been restricted, necessitating the development of alternative structural designs that maintain or exceed performance without using extruded aluminum.
Innovation Solution
The ramp components are formed from aluminum sheet material, cut, stamped, and bent to shape, then welded together, comprising longitudinal support beams and transverse rungs with specific cross-sectional shapes, forming a structurally sound design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If extruded aluminum components are used for ramp construction, then structural performance and durability are improved, but import restrictions and regulatory compliance deteriorate
Solution Approach 1:
The ramp is divided into multiple discrete components including side rails, rungs, cross members, and support beams that can be manufactured separately and assembled together. This segmentation allows each component to be produced using sheet metal forming processes that are not subject to extrusion import restrictions, while maintaining the overall structural integrity of the ramp assembly.
Solution Approach 2:
The ramp construction uses composite assembly of multiple sheet metal components joined through welding and mechanical fastening. Rather than relying on a single extruded aluminum component, the design combines multiple formed sheet metal parts to achieve the required strength and durability, bypassing extrusion import limitations while maintaining structural performance.
2Adaptability or versatility
If sheet metal components are used instead of extruded aluminum, then import restrictions are avoided, but manufacturing complexity increases
Solution Approach 1:
The sheet metal forming process serves multiple functions: it creates the structural components, provides attachment surfaces for welding and fastening, and enables integration of reinforcement features directly into the formed parts. This multi-functionality reduces the need for separate manufacturing steps and component assemblies, thereby simplifying the overall manufacturing process despite using sheet metal instead of extrusions.
3Strength
If sheet metal components are welded together, then structural integrity is maintained, but manufacturing time and energy consumption increase
Solution Approach 1:
Holes, recesses, and attachment features are formed directly into the sheet metal components during the initial forming process before assembly. This preliminary action eliminates the need for post-assembly drilling, tapping, or attachment feature creation, allowing components to be quickly positioned and welded together, thereby reducing overall manufacturing time while maintaining structural integrity.
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 solution provides a structurally superior ramp construction that meets performance standards while avoiding the use of extruded aluminum, ensuring durability and functionality for loading vehicles onto trailers or truck beds.
Implementation Method 1
aluminum sheet material which is cut, stamped and bent to the desired shape
Implementation Method 2
Each of the support rungs is welded to each of the first and second longitudinal support beams
Data Source
AI summary
A ramp includes first and second longitudinal support beams extending in a longitudinal direction, each of the longitudinal support beams being formed from bent aluminum sheet material and having a cross-sectional shape including a laterally outer side wall, a top wall, a bottom wall and a laterally inner longitudinal opening between the top wall and the bottom wall. A plurality of support rungs extend transversely between the support beams, each of the support rungs being formed from bent aluminum sheet material and having a cross-sectional shape including an upper support surface and first and second side walls extending downward from opposite edges of the upper support surface, each of the rungs having first and second ends received through the laterally inner longitudinal openings of the support beams. Each of the support rungs is welded to each of the first and second longitudinal support beams.