Vehicle Mounting Unit Bracket Hardware Integration
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Solution Overview
Problem
Conventional mounting units for coupling a chassis to a vehicle body are complex to manufacture, weigh heavily, and suffer from appearance design deterioration due to thermal deformation during welding.
Innovation Solution
A mounting unit comprising a bracket with multiple bent panels and a hardware component in a hollow cylindrical shape, featuring welding protrusions for projection welding to the bracket, forming a screw thread for engaging bolts, and designed to fit various vehicle body parts with improved structural rigidity and simplified manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional welding method is used to fix bolt to bracket, then bracket and bolt can be firmly connected, but manufacturing process becomes complex and thermal deformation deteriorates appearance design
Solution Approach 1:
The hardware integrates multiple functions into a single component: it combines the bracket structure with the bolt engagement feature. The hollow cylindrical hardware is welded to the bracket as one unit, eliminating the need for separate bracket and bolt components, thereby simplifying the manufacturing process while maintaining connection strength
Solution Approach 2:
The screw thread is pre-formed on the hardware before assembly, and the hardware is pre-welded to the bracket in a controlled manufacturing process. This preliminary preparation of threading and welding allows for simpler final assembly and reduces on-site manufacturing complexity
2Strength
If conventional welding method is used to fix bolt to bracket, then bracket and bolt can be firmly connected, but thermal deformation deteriorates appearance design
Solution Approach 1:
By merging the bracket and hardware into a single welded assembly, the number of welding operations is reduced. The hardware is welded to the bracket in one process rather than separately welding multiple components, minimizing thermal deformation and preserving appearance design
Solution Approach 2:
The invention changes the welding parameters by using projection welding with specifically positioned welding protrusions on the hardware. This controlled welding method concentrates heat in specific areas, reducing overall thermal deformation and protecting the appearance design while ensuring strong connection
3Adaptability or versatility
If multiple separate components are used for mounting unit, then functionality can be achieved, but weight of vehicle increases
Solution Approach 1:
The mounting unit merges multiple functional components into a single integrated hardware piece. The hollow cylindrical hardware combines bracket support, bolt engagement (via internal screw thread), and welding attachment features, eliminating the need for multiple separate components and reducing overall weight
Solution Approach 2:
The hardware is designed as a universal multi-functional component that can serve as both a mounting bracket and a fastener. The internal screw thread allows it to engage bolts while the external shape allows welding to the vehicle body, replacing multiple specialized components with one universal part, thereby reducing weight
4Quantity of substance
If conventional mounting unit manufacturing is used, then brackets and bolts can be produced, but manufacturing process is complex and time-consuming
Solution Approach 1:
The manufacturing process merges the production of brackets and bolts into a single hardware component. This integration allows for simplified production steps, fewer assembly operations, and improved manufacturing efficiency while still providing all necessary mounting unit components
Solution Approach 2:
The screw thread is pre-formed on the hardware during manufacturing, and the welding surfaces are prepared in advance with welding protrusions. This preliminary preparation enables faster final assembly and reduces manufacturing complexity, thereby improving overall productivity
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 solution simplifies the manufacturing process, enhances structural rigidity, ensures high-quality welding, and reduces weight while maintaining design integrity by allowing the mounting unit to be easily applied to various vehicle body parts.
Implementation Method 1
a welding protrusion may be respectively formed at an upper end and a lower end of the hardware along respective circumferences and the hollow of the hardware may be arranged to correspond with a penetration aperture which is respectively bored at an upper plate of the bracket and a lower plate of the bracket, and may be projection-welded to the upper plate and the lower plate of the bracket using the welding protrusion
Data Source
AI summary
A mounting unit is provided that improves compatibility to be applied to various parts of a vehicle body which is coupled with a chassis by manufacturing the mounting unit to include a bracket and hardware. The mounting unit includes a bracket that has a first panel and a second panel, which are respectively bent several times, are combined with each other to form an empty portion to be surrounded by the first panel and the second panel and fixed to a vehicle body. Additionally, the mounting unit includes a hardware that is disposed in the empty portion to be fixed by being combined with the first panel and the second panel and adapted to form a thread for engaging a fastening mechanism.