Space Frame Connector With Curved Weld Surface for Lower Stress Joints
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Solution Overview
Problem
Space frame assemblies in machine chassis face challenges with high stress concentration regions and costly manufacturing due to specialized tooling and fixtures required for joining frame members, which also necessitate differently designed connectors for various frame junctions.
Innovation Solution
A connector with a body and projection that facilitates a full penetration weld joint by defining a curved axial end surface, allowing frame members to be oriented at various angles and reducing the need for specialized tooling through a simple and adaptable design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If frame members are joined by coping and mating with specialized tooling and fixtures, then the frame members can be connected to form frame junctions, but the manufacturing cost and time increase and stress concentration regions are created
Solution Approach 1:
The connector is divided into distinct functional segments: a body portion for joining multiple frame members and a projection portion for providing a welding surface. This segmentation allows each part to perform its specific function optimally, reducing the need for complex tooling and fixtures while minimizing stress concentration at junctions.
Solution Approach 2:
The projection includes a curved surface that contacts the end of the frame member to form a full penetration weld joint. This curvature distributes stress more evenly across the weld interface compared to flat surfaces, reducing stress concentration regions while maintaining reliable connections without requiring specialized coping operations.
2Adaptability or versatility
If differently designed connectors are used at different frame junctions, then each junction can be optimized for its specific configuration, but the device complexity and manufacturing cost increase
Solution Approach 1:
The connector body is designed with a universal geometry that can accommodate multiple frame members at various angles. The projection's curved surface can contact frame member ends at different orientations, allowing a single connector design to serve multiple junction configurations. This multi-functionality reduces the need for differently designed connectors while maintaining adaptability to various frame geometries.
3Adaptability or versatility
If frame members are positioned at various angles during assembly, then the space frame assembly can achieve complex geometries, but the alignment precision and manufacturing time are affected
Solution Approach 1:
The curved surface of the projection provides a continuous contact interface that guides the frame member end into proper alignment during the welding process. This curved geometry maintains alignment precision across various angles by distributing contact forces evenly, allowing complex frame geometries to be assembled with consistent precision without requiring specialized positioning tooling.
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 connector enables efficient alignment and strengthening of frame members, reduces stress concentration, and simplifies assembly and disassembly, thereby lowering manufacturing costs and time while enhancing the load-bearing capacity of the space frame assembly.
Implementation Method 1
facilitate formation of a full penetration weld joint between an end of the frame member and the axial end surface
Data Source
AI summary
A connector for connecting a frame member to one or more other frame members of a space frame assembly is disclosed. The connector includes a body defining a surface and a projection extending outwardly from the surface along a main axis to define an axial end surface away from the surface. The axial end surface defines a curvature having continuity across an expanse of the axial end surface to facilitate formation of a full penetration weld joint between an end of the frame member and the axial end surface upon a contact of the end of the frame member with the axial end surface.