Variable-Stiffness Vehicle Structure to Protect the Weld Line
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle structures face challenges in controlling deformation behavior during transverse impacts due to the presence of stiffening inserts at weld lines, leading to potential failure at these points, and current solutions to enhance stiffness are costly.
Innovation Solution
A vehicle structure design where the stiffening insert extends beyond the weld line, distributing impact stresses to a more deformable part, thereby avoiding failure at the weld line and allowing controlled deformation patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the stiffening insert extends into the second part of the structural element reaching the weld line, then the stiffness of the second part is increased, but the deformations are concentrated around the weld line leading to potential failure at this point
Solution Approach 1:
The stiffening insert is segmented into two distinct parts: a first portion extending into the first part of the structural element and a second portion extending into the second part. This segmentation allows different regions of the insert to serve different functions - the first portion in the more deformable first part and the second portion in the stiffer second part, thereby distributing stresses away from the weld line while maintaining overall structural integrity
Solution Approach 2:
The stiffening insert is designed with varying local properties - the first portion has different dimensional characteristics (length, cross-sectional area, thickness) compared to the second portion. This local quality variation allows the insert to adapt to the different stiffness requirements of the first and second parts while preventing stress concentration at the weld line interface
2Reliability
If the structural element is manufactured in a single piece with different thicknesses or heat treatments, then the deformation behavior is better controlled, but the manufacturing cost increases significantly
Solution Approach 1:
The stiffening insert is integrated with the structural element by extending into both the first and second parts, effectively merging two separate components (the structural element and the stiffening insert) into a unified assembly. This integration achieves the desired deformation control without requiring expensive single-piece manufacturing with variable thickness or heat treatment
Solution Approach 2:
The stiffening insert acts as an intermediary element that mediates between the first part and the second part of the structural element. By extending into both parts, it transfers and distributes stresses appropriately, controlling the deformation behavior during impact without requiring complex manufacturing processes for the structural element itself
Data Source
Figure 1~2
Figure 3~4
AI summary
A vehicle comprises a structure (SV) comprising an element (ES) comprising a first portion (P1) and second portion (P2) which extend from each other at a weld line (LS) and which have a first stiffness and a second stiffness which is strictly greater than the first stiffness. The first portion (P1) and second portion (P2) together define a cavity (LI) which houses a stiffening insert (IR) which extends on either side of the weld line (LS) in order to move the stresses undergone by the element (ES) in the event of an impact away from the weld line (LS) by shifting them into the first portion (P1).