Vehicle Frame Joining Structure with Slit-Dispersion Welding
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Solution Overview
Problem
Existing vehicle frame joining structures fail to ensure withstand load strength and robustness when subjected to bending deformation, as arc-welded portions can break under load input from collisions, leading to inadequate load absorption.
Innovation Solution
A joining structure comprising a tubular first frame formed by extrusion molding and an open-cross section second frame by die-casting, with a slit portion and strategically positioned welded portions to disperse bending stress, ensuring that the load is absorbed efficiently through controlled bending deformation without concentrating stress at a single welded point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single arc-welded portion is used to join the mounting bracket to the extruded member, then the structure is simple, but the welded portion breaks under collision load and the frame cannot absorb the load
Solution Approach 1:
The joining structure is divided into multiple welded portions (first welded portion at the marginal edge and second welded portion at the slit portion) instead of a single welded connection. This segmentation distributes the collision load across multiple weld points, preventing any single welded portion from breaking under excessive stress, thereby resolving the contradiction between strength and simplicity.
Solution Approach 2:
The slit portion is strategically positioned and sized to create localized stress distribution characteristics. By controlling the geometry and position of the slit portion, the structure achieves optimal stress distribution at critical welded portions while maintaining overall structural integrity, addressing the contradiction between strength enhancement and structural complexity.
2Loss of energy
If the extruded member is designed to deform by bending to absorb load, then energy absorption is improved, but the arc-welded portions break due to concentrated bending stress
Solution Approach 1:
Multiple welded portions are created along the joining structure, including the first welded portion at the marginal edge and the second welded portion at the slit portion. This segmentation allows bending stress to be distributed across multiple weld points rather than concentrated at a single location, enabling the extruded member to deform and absorb energy while maintaining welded portion reliability.
Solution Approach 2:
The slit portion acts as an intermediary element that modifies the stress distribution pattern during bending deformation. By introducing this controlled geometric feature, the structure facilitates stress transfer and distribution that protects the welded portions from breakage while allowing the desired bending deformation for energy absorption.
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 proposed structure effectively disperses bending stress across multiple welded portions, preventing breakages and ensuring robustness and efficient load absorption, thereby enhancing the vehicle frame's ability to withstand collisions.
Implementation Method 1
a first welded portion structured by welding of the marginal edge portion of the second frame to the first frame, and a second welded portion structured by welding of a periphery edge portion of the slit portion to the first frame
Implementation Method 2
the first frame being formed in a closed cross section shape by extrusion molding of a lightweight metal... when a load is inputted to the first frame from an extension direction one end portion side thereof by a vehicle collision or the like, because of the difference in strength between the first frame and the second frame, the extension direction one end portion of the first frame deforms by bending toward the second frame
Data Source
AI summary
A joining structure of a vehicle frame that includes: a vehicle frame including a tubular first frame and a second frame, the first frame being formed in a closed cross section shape by extrusion molding of a lightweight metal, the second frame being formed in an open cross section shape of which one side is open by die-casting of a lightweight metal, and the second frame being superposed with the first frame in a state of contact therewith; a slit portion formed in the second frame, the slit portion extending along a marginal edge portion at an opening direction side of the second frame; a first welded portion structured by welding the marginal edge portion of the second frame to the first frame; and a second welded portion structured by welding a periphery edge portion of the slit portion to the first frame.