Commercial Vehicle Windshield Flange Offset Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current body structures for commercial vehicles face challenges in reliably implementing perfect spot weld connections due to alignment issues between four-layer connection points, leading to inconsistent and unreliable welds across different vehicle variants.
Innovation Solution
The position of the second three-layer connection point is offset transversely in both vehicle variants, ensuring a two- or three-layer flange connection throughout the windscreen flange, preventing alignment and allowing for reliable three-layer structures at both connection points, with the cross member console part acting as a transverse guide to compensate for manufacturing tolerances and provide additional functions like sun visor mounting points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the first three-layer connection point and second three-layer connection point are aligned vertically, then the structure is simplified, but the spot weld connection becomes unreliable
Solution Approach 1:
The patent resolves the vertical alignment conflict by introducing a transverse offset dimension. Instead of keeping both connection points aligned in the vertical direction (one dimension), the second connection point is deliberately offset in the transverse direction (another dimension), transforming the problem from a vertical stacking issue to a spatial distribution issue that avoids four-layer overlap while maintaining structural simplicity
2Adaptability or versatility
If the cross member console part length is increased to accommodate both vehicle variants, then adaptability to different variants is improved, but component complexity increases
Solution Approach 1:
The cross member console part is designed as a universal component with extended length that can accommodate both vehicle variants (reduced roof height and greater roof height) through transverse offset adjustment. This single extended component replaces the need for variant-specific components, achieving multi-functionality without increasing overall system complexity
Solution Approach 2:
The patent utilizes parameter changes in the transverse offset distance to adapt the same cross member console part to different vehicle variants. By varying the transverse offset parameter within the extended console part, the structure accommodates different roof duct positions without requiring different component geometries or additional parts
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a body structure for a commercial vehicle, comprising a roof outer skin (7) and a side outer skin (11), each having front transverse flanges (23, 25). These form a common windshield flange for a windshield (1) and are overlapping at a first three-layer connection point (A1), in particular a weld point, and supported on a cross member flange (27) of a cross member profile (29). At the first three-layer connection point (A1), the transverse flanges (23, 25) of the roof and side outer skins (7, 11) meet their longitudinal flanges (19, 21), which form a roof channel (9).Furthermore, the crossbeam profile (29) is constructed from a crossbeam center section (31) and at least one crossbeam bracket section (33), which overlap at a second three-layer connection point (A2), in particular a weld point, and are connected to one of the front transverse flanges (23, 25) of the roof and side outer skin (7, 11). According to the invention, in both the first vehicle variant (I) and the second vehicle variant (II), the two three-layer connection points (A1, A2) are spaced apart from each other by a transverse offset (Δy1, Δy2).