Vehicular Sub-Frame Mount With Auxiliary Cup
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Solution Overview
Problem
The conventional sub-frame mount configuration has a deep main cup, making it difficult to insert and position welding tools for coupling the upper and lower plates with the main cup, leading to fabrication challenges and improper welding.
Innovation Solution
A structure featuring a main cup with an auxiliary cup of larger diameter, reducing the forming depth and allowing easy tool insertion, while increasing sectional rigidity through area contact welding between the auxiliary cup and lower plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a deep main cup is used to couple the upper and lower plates, then the coupling strength is improved, but the accessibility for welding tools deteriorates
Solution Approach 1:
The single deep main cup is segmented into two cups: a main cup and an auxiliary cup positioned adjacent to it. This segmentation reduces the depth of each individual cup while maintaining the overall coupling strength through the combined structure, thereby improving welding tool accessibility.
Solution Approach 2:
Instead of increasing depth in the vertical dimension, the solution adds a horizontal dimension by positioning the auxiliary cup adjacent to the main cup. This dimensional transition allows welding tools to access the coupling area from the side, resolving the accessibility issue while maintaining structural strength.
2Strength
If the main cup depth is increased to enhance coupling, then the coupling strength is improved, but the manufacturing difficulty increases
Solution Approach 1:
Dividing the deep main cup into two shallower cups (main cup and auxiliary cup) simplifies the forming process for each cup individually, reducing manufacturing difficulty while achieving the required coupling strength through their combined structure.
Solution Approach 2:
By transitioning from a deep vertical structure to a shallower horizontal structure with two adjacent cups, the manufacturing process becomes easier as each cup requires less depth, while the horizontal arrangement maintains the necessary coupling capability.
3Ease of operation
If the main cup depth is reduced to improve tool accessibility, then the welding accessibility is improved, but the coupling strength deteriorates
Solution Approach 1:
The main cup and auxiliary cup are merged in function to provide both coupling strength and tool accessibility. The auxiliary cup, positioned adjacent to the main cup, works together with it to maintain overall coupling strength while enabling better welding tool access.
Solution Approach 2:
The auxiliary cup provides an alternative access path in the horizontal dimension, allowing welding tools to reach the coupling area without requiring excessive vertical depth, thus maintaining both accessibility and strength.
4Stability of the object's composition
If the auxiliary cup diameter is increased to enhance rigidity, then the sectional rigidity is improved, but the material usage increases
Solution Approach 1:
The auxiliary cup is designed with a larger diameter specifically at the region where rigidity is needed, while maintaining appropriate thickness and material distribution. This local quality optimization provides enhanced sectional rigidity without unnecessarily increasing overall material usage.
Solution Approach 2:
The combination of main cup and auxiliary cup creates a composite structural system where the larger diameter auxiliary cup provides rigidity enhancement. The material is strategically distributed between the two cups to achieve optimal rigidity-to-material-ratio.
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
Facilitates easy and firm welding by reducing the forming depth of the sub-frame mount, enabling tool access and enhancing sectional rigidity through wider contact areas.
Implementation Method 1
A sub-frame pipe 6 interposed by a bush 6a is pressure-fitted into both ends of the sub-frame 7 facing toward a front of the bodywork
Implementation Method 2
each welded on its one end... welded with the main cup 7c... welded with the sub-frame support panel 2
Data Source
AI summary
A structure of a mount of a vehicular sub-frame includes a main cup into which a sub-frame pipe can be pressure-fitted, an upper plate coupled to the main cup, an auxiliary cup coupled to one end of the main cup, and a lower plate coupled to the auxiliary cup.