Side Wall Outer Panel Structure for A-Pillar Corner Stamping
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Solution Overview
Problem
Existing vehicle designs struggle to balance styling effect and optimize the upper view angle while addressing issues of cracking, material stacking, and wrinkling at the sharp corners where the A-pillar outer trim panel and roof trim panel converge.
Innovation Solution
A side wall outer panel structure comprising multiple plate bodies and connecting plates with arc-shaped ridges, spherical rounded corners, sloping triangular ribs, and wrinkle absorbing ribs, designed to support and connect with the roof trim panel and A-pillar outer trim panel, optimizing the stamping process and reducing cracking and wrinkling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the upper boundary of the front windshield is shortened downwards to reduce stamping depth at the A-pillar, then the stamping problem of the side wall outer panel is solved, but the front upper view angle is sacrificed and the black edge width increases
Solution Approach 1:
The side wall outer panel is divided into multiple plate bodies (first, second, third plate bodies) connected by connecting plates, with different regions承担 different functions. The first plate body handles the A-pillar area with arc-shaped ridges, the second plate body connects the front windshield and roof trim panel, and the third plate body connects the outer trim panel, allowing each segment to be optimized independently for both manufacturing and appearance.
Solution Approach 2:
Arc-shaped ridges and spherical rounded corners are introduced at the sharp corners of the first plate body to replace traditional straight edges and sharp corners. This curvature design reduces stress concentration during stamping, facilitates the forming process, and simultaneously maintains good styling effect and upper view angle without requiring shortening of the front windshield boundary.
2Ease of manufacture
If simple and smooth outer ridges are designed at sharp corners to facilitate drawing and forming, then the manufacturing process is simplified, but cracking and stacking at sharp corners remain difficult to resolve
Solution Approach 1:
Spherical rounded corners are formed at the sharp corners where arc-shaped ridges meet, replacing traditional straight edges and sharp corners. This curvature design distributes stress more evenly during stamping and forming processes, significantly reducing the occurrence of cracking and stacking while still facilitating drawing and forming operations.
Solution Approach 2:
The geometry parameters of the ridges are optimized by introducing arc-shaped profiles with specific radii and spherical rounded corners with controlled dimensions. These parameter changes balance the competing requirements of ease of forming and resistance to cracking, allowing the material to flow more smoothly during stamping without concentrating stress at sharp corners.
3Productivity
If the structural design at the connecting positions of the side wall outer panel with the A-pillar outer trim panel and roof trim panel is optimized, then material utilization and manufacturing process are improved, but cracking, stacking, and wrinkling at these positions remain challenging
Solution Approach 1:
The side wall outer panel is segmented into multiple plate bodies and connecting plates, with each component having specific functions. The first plate body connects with the A-pillar outer trim panel and roof trim panel, featuring arc-shaped ridges and spherical rounded corners. The second plate body connects the front windshield and roof trim panel, while the third plate body connects the outer trim panel. This segmentation allows independent optimization of each component for both material utilization and surface quality.
Solution Approach 2:
The geometry parameters of the ridges and corners are optimized with specific arc radii and spherical corner dimensions. These parameter changes control material flow during stamping, preventing cracking, stacking, and wrinkling at the connecting positions while improving material utilization and manufacturing efficiency.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A side wall outer plate (4b) and a vehicle. The side wall outer plate (4b) comprises a first plate body (101), a second plate body (102), a third plate body (103), a first connecting plate (111), a second connecting plate (112) and a third connecting plate (113). The first connecting plate (111), the second connecting plate (112) and the third connecting plate (113) are connected to each other; the first connecting plate (111) is respectively connected to the first plate body (101) and the second plate body (102); the second connecting plate (112) is respectively connected to the first plate body (101) and the third plate body (103); and the third connecting plate (113) is respectively connected to the second plate body (102) and the third plate body (103). The first plate body (101) is provided with a first arc-shaped ridge line (31b), a second arc-shaped ridge line (32b) and a straight ridge line (33b), wherein a first spherical rounded corner (82) is formed between the first arc-shaped ridge line (31b) and the second arc-shaped ridge line (32b); a second spherical rounded corner (81) is formed between the first arc-shaped ridge line (31b) and the straight ridge line (33b); the first arc-shaped ridge line (31b) and the straight ridge line (33b) are used for abutting against a top cover trim plate (2b); and the second arc-shaped ridge (32b) is used for abutting against an outer trim plate (5b). The second plate body (102) is used for connecting a front windshield (1b) and the top cover trim plate (2b). The third plate body (103) is used for connecting the outer trim plate (5b).