Stamped Steel Front Sub-Assembly with Integrated Dampener
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Solution Overview
Problem
Conventional front sub-assemblies for vehicle chassis are heavy and costly due to the use of multiple components, which hinders weight reduction and complexity, while compromising on safety and rigidity.
Innovation Solution
A front sub-assembly design featuring a reduced number of parts, including spaced apart hollow side assemblies with strategically placed brackets and internal mass dampeners, formed from stamped steel, to achieve weight reduction without sacrificing strength or safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple individual frame components are used in conventional front sub-assemblies, then structural strength and rigidity are achieved, but weight increases and manufacturing cost increases
Solution Approach 1:
The patent combines multiple individual frame components into integrated side assemblies where upper and lower side members are formed as single stamped pieces rather than separate components. This merging reduces the total number of parts while maintaining structural integrity through optimized stamping designs that incorporate reinforcement features directly into the formed components.
Solution Approach 2:
The invention changes the manufacturing parameters by using stamped steel components with varying thicknesses and densities in different zones of the side assemblies. This allows weight optimization in non-critical areas while maintaining sufficient strength in load-bearing regions through parameter variations in the stamping process.
2Device complexity
If multiple individual frame components are welded together, then necessary structural configuration is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges multiple welded components into single stamped pieces, eliminating complex welding operations. The side assemblies are formed as integrated units through stamping processes, significantly reducing manufacturing steps, assembly time, and welding-related costs while achieving the necessary structural configuration.
Solution Approach 2:
The invention extracts the welding process entirely from the manufacturing sequence by using cold-formed stamped components that are assembled through alternative means. This removes a complex and costly manufacturing step while maintaining structural requirements through design optimizations in the stamped components themselves.
3Reliability
If conventional multi-component front sub-assemblies are used, then safety requirements are met, but weight reduction goals are hindered
Solution Approach 1:
The patent applies parameter changes by using variable thickness stamping where material density and thickness are optimized for each specific zone of the side assemblies. This allows weight reduction in non-critical areas while maintaining sufficient strength and safety performance in load-bearing regions through controlled parameter variations.
Solution Approach 2:
The invention applies local quality by concentrating material and structural reinforcement only where needed for safety-critical functions. The stamped side assemblies feature localized thickening and reinforcement at specific points rather than uniform heavy construction throughout, achieving safety requirements with minimized overall weight.
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 design achieves weight reduction while maintaining safety and rigidity, enhancing fuel economy by minimizing the number of components and utilizing stamped steel for structural elements.
Implementation Method 1
The front cross member includes a front cross member reinforcing bracket and an internal mass dampener
Data Source
AI summary
A front sub-assembly for an automotive vehicle is disclosed. The front sub-assembly includes a pair of spaced apart, substantially hollow side assemblies. Each of the side assemblies includes an upper side member and a lower side member. The front ends of the side assemblies are joined together by a front cross member that includes a front cross member reinforcing bracket and an internal mass dampener. The rear ends of the side assemblies are joined by an upper cross member and a lower cross member. A plurality of brackets, including body mount brackets, a steering gear bracket, an exhaust mount bracket, and a roll restrictor bracket are also strategically provided. The brackets as well as other components are preferably formed from stamped steel.