Side Sill Reinforcement Structure for Divided EV Body Assembly
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Solution Overview
Problem
The existing side sill structures in electric vehicles, divided into multiple parts, lack sufficient reinforcement around the dividing line, leading to potential fractures and increased assembly costs due to separate in-line assembly processes, which is a challenge when converting internal combustion vehicle production lines to electric vehicle production.
Innovation Solution
A side sill reinforcement structure with pre-assembled stiffeners and coupling protrusions that enhance connectivity around the dividing line, eliminating the need for separate assembly processes by integrating stiffeners into the side sill inner and outer panels before coupling, using different rigidity levels for localized reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the side sill is divided into multiple parts for assembly performance, then assembly ease is improved, but structural integrity around the dividing line deteriorates
Solution Approach 1:
The side sill inner panel is divided into multiple parts (first, second, and third parts) that can be assembled separately and then coupled together. This segmentation allows for easier manufacturing and assembly while the coupling protrusions provide reinforcement at the joining locations to maintain structural integrity.
Solution Approach 2:
Coupling protrusions are pre-formed on the side sill outer panel at locations corresponding to the dividing lines. These protrusions are prepared in advance during manufacturing, so that when the inner panel parts are assembled and coupled together, the structural reinforcement is already in place, eliminating the need for additional reinforcement steps.
2Stability of the object's composition
If proper welding is applied to divided parts, then rigidity is improved, but manufacturing complexity increases
Solution Approach 1:
Coupling protrusions serve as intermediary structural elements that are pre-formed on the side sill outer panel. These protrusions act as mediators that provide reinforcement at the dividing lines where inner panel parts are coupled, reducing the need for complex welding operations while maintaining rigidity.
3Reliability
If adequate reinforcement is provided in the side sill, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
Coupling protrusions are pre-formed on the side sill outer panel during the manufacturing process. This preliminary action ensures that reinforcement is already in place before assembly, improving reliability to prevent fractures at dividing lines while avoiding the need for additional costly reinforcement operations during assembly.
Data Source
AI summary
An embodiment is a side sill reinforcement structure of a vehicle, the structure including a side sill inner panel divided into a plurality of parts and having a first stiffener inserted into each of the plurality of parts, and a side sill outer panel coupled to the side sill inner panel facing a dividing line of the side sill inner panel to constitute a side sill, having fixed therein a reinforcing member extending in a lengthwise direction, and having a second stiffener, configured to support the reinforcing member.