Vehicle Support Structure Attachment Insert Stiffness
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Solution Overview
Problem
Existing vehicle support structures face challenges in achieving desired stiffness at attachment points while minimizing mounting space and maintaining low deformation behavior, as conventional designs often compromise on stiffness due to limited space and additional components required for attachment points.
Innovation Solution
The support structure incorporates separate attachment inserts with an upper chord, lower chord, and back section, connected to the shells via welding, which provide attachment points and increase stiffness by separating the link connection part receivers from the support cavity, allowing for narrower tolerance limits and reduced component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If attachment points are arranged on the outer side of the support using additional components, then the support strength is maintained, but the mounting space requirement increases
Solution Approach 1:
The attachment insert merges multiple functions into a single component: it provides attachment points for links, strengthens the support structure through its chord-and-back-section geometry, and integrates directly with the upper and lower shells. This eliminates the need for separate additional components while maintaining support strength.
Solution Approach 2:
The attachment insert utilizes the space between the upper and lower shells by extending into the cavity dimension. The back section of the insert spans this cavity, creating a three-dimensional structure that provides attachment points without increasing the external mounting footprint of the support.
2Area of stationary object
If attachment points are arranged between the shells using a link connection part, then the mounting space is reduced, but the stiffness at attachment points deteriorates
Solution Approach 1:
The attachment insert employs local quality enhancement by concentrating material and structural complexity at the attachment point regions. The upper and lower chords with their integrated link connection part receivers create locally reinforced zones that maximize stiffness where needed, while the rest of the support structure maintains its original design.
Solution Approach 2:
The attachment insert functions as a composite structural element combining the upper chord, lower chord, and back section into an integrated stiffening structure. This composite geometry creates a rigid framework that resists deformation at the attachment points while maintaining overall support flexibility.
3Ease of manufacture
If the support structure uses a modular design with shells connected by walls, then the manufacturing ease is improved, but the deformation behavior worsens
Solution Approach 1:
The support structure maintains its modular segmented design with separate upper and lower shells that are easier to manufacture independently. The attachment insert is introduced as an additional segmented element that bridges these shells, providing local stiffening without requiring the entire support structure to be manufactured as a single complex piece.
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 enhances stiffness and reduces deformation, enabling the support structure to handle additional components and forces without additional mounting elements, while optimizing weight and reducing production costs.
Implementation Method 1
The attachment insert (10) is connected to the upper shell (3) and to the lower shell (4)
Data Source
AI summary
The present disclosure relates to a support structure (1) for a vehicle, comprising a support (2) which has an upper shell (3) and a lower shell (4), the extension of the support structure in the longitudinal extension of the vehicle being defined by the extension of the two shells (3, 4) in said direction, and comprising attachment points (14, 14.1) for connecting a link (27). A front attachment point and a rear attachment point are provided on each link attachment side (9, 9.1). The two attachment points (14, 14.1) are provided for an attachment insert (10) on each link attachment side (9, 9.1) of the support (2), wherein the attachment insert is connected to the shells (3, 4), is open towards a link (27) to be connected to the attachment points at least in the region of the attachment points (14, 14.1), and is produced as a separate component. This attachment insert has an upper chord (11), a lower chord (12), and a back section (13) connecting the upper chord (11) to the lower chord (12), wherein the upper chord (11) of the attachment insert (10) is connected to the upper chord (11) of the support (2), and the lower chord (12) of the attachment insert (10) is connected to the lower shell (4) of the support (2), wherein link connection part receivers (17, 17.1) provided by the attachment insert (10) are separated from the support (2) cavity located between the upper and the lower shell by the back section (13).