UHSS Structural Beam with Flat Joining Region for Welding
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Solution Overview
Problem
Current structural beams in vehicles, particularly B-pillars and bumpers, face challenges in withstanding twisting forces and crash impacts while maintaining weight efficiency, as existing reinforcement methods often require perfect fitting and can lead to weight increase and complex joining processes.
Innovation Solution
A structural beam design featuring a U-shaped cross-section with a flat joining region on the bottom wall, allowing for welding of reinforcements without the need for perfect fitting, combined with remote laser welding to reduce weight and improve mechanical behavior under twisting and bending forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional reinforcement methods are used to strengthen structural beams against twisting forces, then the strength and stiffness are improved, but the weight increases and the joining process becomes more complex
Solution Approach 1:
The structural beam is divided into a first beam component and a separate reinforcement component that can be joined together. This segmentation allows each component to be optimized independently and simplifies the joining process by creating dedicated joining regions with flat surfaces that require perfect fitting, while the overall structure achieves the desired strength and stiffness through the combination of components.
2Strength
If traditional reinforcement methods are used to strengthen structural beams, then the mechanical behavior under impact is improved, but the manufacturing complexity increases
Solution Approach 1:
The first beam and reinforcement are designed with predetermined flat joining regions that are prepared in advance during manufacturing. These pre-prepared joining regions with flat surfaces eliminate the need for complex adjustment and fitting operations during assembly, thereby reducing manufacturing complexity while ensuring proper alignment and connection for improved impact resistance.
3Weight of moving object
If hardened UHSS is used to maintain weight efficiency, then the weight is reduced, but the joining process becomes more difficult due to material hardness
Solution Approach 1:
The joining regions of both the first beam and reinforcement are designed with flat surfaces that provide localized areas optimized for joining operations. This local quality enhancement at the joining regions facilitates easier connection of hardened UHSS components by creating predetermined contact surfaces that reduce the difficulty of joining, while the rest of the components maintain their hardened state for weight efficiency.
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
This design enables the use of hardened UHSS without weight increments, enhances structural integrity under impact and twisting forces, and simplifies the joining process, reducing manufacturing time and complexity.
Implementation Method 1
The first beam and the reinforcement are welded together at first and second joining regions
Implementation Method 2
remote laser welding to reduce weight and improve mechanical behavior under twisting and bending forces
Data Source
AI summary
A structural beam which comprises a first beam and a reinforcement to be attached to it. The first beam has a substantially U-shaped cross-section along at least a first portion of its length and comprises a bottom wall and two sidewalls wherein the bottom wall comprises a substantially flat first joining region. The reinforcement of the structural beam has a substantially flat second joining region which may be welded to a first joining region. Both parts of the structure are made of hardened UHSS. Methods for manufacturing such beams are also provided.