Sheet Metal Profile Steering Head Assembly for Two-Wheelers
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Solution Overview
Problem
Existing assemblies for two-wheelers, trikes, or quads face a trade-off between weight and structural rigidity, requiring heavy components to achieve adequate stability, which is inefficient and costly.
Innovation Solution
The use of formed sheet metal profile parts, particularly with a C-shaped cross-section, to connect the steering head to a supporting part, forming a battery box, which provides comparable or superior structural rigidity while reducing weight, and can be easily manufactured with cost savings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel tubes or cast components are used to connect the steering head to the supporting part, then structural rigidity is achieved, but weight increases significantly
Solution Approach 1:
The patent changes the geometric parameters of the connecting component by using a formed sheet metal profile with optimized cross-sectional shape instead of traditional steel tubes. The profile is bent from sheet metal to create specific geometric configurations that maximize rigidity while minimizing material usage and weight.
Solution Approach 2:
The patent employs composite construction by combining sheet metal forming with strategic reinforcement elements. The formed profile creates a composite structure that achieves steel-like rigidity with aluminum or other lightweight sheet materials, reducing overall assembly weight while maintaining structural integrity.
2Weight of moving object
If formed sheet metal profile parts are used to connect the steering head, then weight is reduced and manufacturing cost decreases, but structural rigidity must be maintained
Solution Approach 1:
The patent optimizes the geometric parameters of the formed profile including wall thickness, cross-sectional shape, and bending radius to achieve the required rigidity-to-weight ratio. The profile geometry is specifically designed to maximize moment of inertia and structural efficiency.
Solution Approach 2:
The patent transitions from one-dimensional tubular structures to two-dimensional formed sheet metal profiles with complex cross-sectional geometries. This dimensional change allows for more efficient stress distribution and higher rigidity per unit weight through optimized surface area and cross-sectional configuration.
3Strength
If complex deep-drawing processes are used to form profile parts, then structural integrity is maintained, but manufacturing complexity and cost increase
Solution Approach 1:
The patent divides the profile formation process into simpler stages, using bending and forming operations instead of complex deep-drawing. The profile may be constructed from multiple simpler formed pieces that are joined together, reducing the complexity of individual forming operations while maintaining overall structural integrity.
Solution Approach 2:
The patent employs formed sheet metal profiles that can be manufactured using simpler, more cost-effective processes compared to traditional deep-drawing or casting. The formed profiles are designed to achieve required performance through geometry optimization rather than complex manufacturing processes.
Data Source
Figure 1~2
Figure 3
AI summary
A sub-assembly (10) for a bike, trike or quad, more particularly for a motorcycle or a motor scooter, comprises a steering head (12) and at least one profile element (14) connecting the steering head (12) to a supporting part (16) of the bike, trike or quad, more particularly to a main frame, engine housing or battery casing or a part thereof. The profile element (14) in the sub-assembly is made from a shaped piece of sheet metal.