阅读说明：本技术 用于矩形管拐角应力释放的通用铸件 (Universal casting for releasing stress of corner of rectangular pipe ) 是由 杰弗瑞·W·霍格 约翰·R·盖尔 于 2020-02-25 设计创作，主要内容包括：一种角撑板结构包括主体,所述主体具有形成板配合表面的板接触端部并且从所述板接触端部延伸到远端端部。所述主体限定在所述板接触端部与所述远端端部之间延伸的管配合表面。所述板配合表面与板接合。所述管配合表面包括第一表面部分和第二表面部分,在第一表面部分和第二表面部分之间形成内表面角。所述内表面角具有设置在顶点轴线上的顶点,所述顶点轴线与板配合表面相交。所述第一表面部分接合细长构件的第一侧壁。所述第二表面部分接合所述细长构件的第二侧壁。所述主体从所述远端端部朝向所述板接触端部向外张开,以将所述板中的应力从所述细长构件的拐角分散在更大的区域上。(A gusset structure includes a body having a plate contacting end forming a plate mating surface and extending from the plate contacting end to a distal end. The body defines a tube mating surface extending between the plate contact end and the distal end. The plate mating surface engages the plate. The tube mating surface includes a first surface portion and a second surface portion with an inner surface angle formed between the first surface portion and the second surface portion. The inner surface angle has an apex disposed on an apex axis that intersects the board mating surface. The first surface portion engages a first sidewall of the elongated member. The second surface portion engages a second sidewall of the elongated member. The body flares outwardly from the distal end toward the plate contacting end to distribute stresses in the plate over a larger area from corners of the elongated member.)

1. A gusset construction for distributing stresses formed at a junction between a plate and an elongate member, the gusset construction comprising:

a body having a plate contacting end forming a plate mating surface for engaging the plate;

wherein the body forms a tube mating surface having a first surface portion and a second surface portion that form an inner surface angle therebetween and that extend away from the plate contact end, wherein the inner surface angle has an apex disposed on an apex axis that intersects the plate mating surface;

wherein a first surface portion of the tube mating surface is positioned for engaging a first sidewall of the elongated member and a second surface portion of the tube mating surface is positioned for engaging a second sidewall of the elongated member.

2. The gusset structure of claim 1, wherein the body comprises a distal end spaced a length from the plate contacting end along the apex axis, wherein the tube mating surface extends between and interconnects the plate contacting end and the distal end of the body.

3. The gusset construction of claim 2, wherein the plate mating surface defines a first region and the distal end forms an end surface defining a second region, wherein the first region of the plate mating surface is larger than the second region of the end surface.

4. The gusset structure of claim 2, wherein the body comprises a cross-sectional area perpendicular to the apex axis, wherein the cross-sectional area of the body increases in size with movement along the apex axis in a direction from the distal end toward the plate contacting end.

5. The gusset structure of claim 4, wherein the cross-sectional area of the body varies along the apex axis at a variable rate of change per unit length.

6. The gusset structure of claim 1, wherein a first surface portion of the tube mating surface defines a first outer edge at an intersection of the first surface portion and an outer surface of the body, and wherein a second surface portion of the tube mating surface defines a second outer edge at an intersection of the second surface portion and the outer surface of the body.

7. The gusset structure of claim 6, further comprising: a first distance between the apex axis and the first outer edge at the distal end of the body; and a second distance between the apex axis and the first outer edge at the plate contacting end, wherein the first distance is less than the second distance.

8. The gusset structure of claim 7, further comprising: a third distance between the apex axis and the second outer edge at the distal end of the body; and a fourth distance between the apex axis and the second outer edge at the plate contacting end, wherein the third distance is less than the fourth distance.

9. The gusset structure of claim 8, wherein the first distance and the third distance are substantially equal, and wherein the second distance and the fourth distance are substantially equal.

10. The gusset structure of claim 1, wherein the plate mating surface forms a partially rounded shape.

11. The gusset structure of claim 1, wherein the tube mating surface comprises a third surface portion interconnecting the first and second surface portions.

12. The gusset construction of claim 11, wherein the third surface portion comprises a cross-sectional shape perpendicular to the apex axis, the cross-sectional shape forming an arcuate shape and sized to mate with a rounded corner of the elongated member interconnecting the first and second sidewalls of the elongated member.

13. The gusset structure of claim 1, wherein the plate mating surface is substantially perpendicular to the apex axis.

14. The gusset structure of claim 1, wherein the body is magnetized.

15. The gusset structure of claim 1, further comprising a removable handle extending outwardly from the body.

16. A structural assembly, comprising:

a plate;

an elongated member attached to the plate;

wherein the elongate member extends along a central longitudinal axis and comprises a first sidewall and a second sidewall disposed adjacent to each other and positioned to form an inner wall angle therebetween;

wherein the plate is positioned transverse to a central longitudinal axis of the elongated member; and

a gusset structure attached to both the plate and the elongate member, the gusset structure comprising:

a body having a plate contacting end forming a plate mating surface in abutting engagement with the plate;

wherein the body forms a tube mating surface having a first surface portion and a second surface portion that form an inner surface angle therebetween and that extend away from the plate contacting end, wherein the inner surface angle has an apex disposed on an apex axis that intersects the plate mating surface, and wherein the inner surface angle is substantially equal to the inner wall angle;

wherein a first surface portion of the tube mating surface is disposed against a first sidewall of the elongated member and a second surface portion of the tube mating surface is disposed against a second sidewall of the elongated member;

wherein the body includes a distal end spaced a length from the plate contacting end along the apex axis, wherein the tube mating surface extends between and interconnects the plate contacting end and the distal end of the body; and is

Wherein the plate mating surface defines a first area and the distal end forms an end surface defining a second area, wherein the first area of the plate mating surface is larger than the second area of the end surface.

17. The structural assembly of claim 16, wherein the body includes a cross-sectional area perpendicular to the apex axis, wherein the cross-sectional area of the body increases in size with movement along the apex axis in a direction from the distal end toward the plate contact end.

18. The structural assembly of claim 16, wherein:

the first surface portion of the tube mating surface defines a first outer edge at an intersection of the first surface portion and the outer surface of the body;

the body defines a first distance between the apex axis and the first outer edge at a distal end of the body;

the body defines a second distance between the apex axis and the first outer edge at the plate contacting end;

the first distance is less than the second distance;

a second surface portion of the tube mating surface defining a second outer edge at an intersection of the second surface portion and an outer surface of the body;

the body defines a third distance between the apex axis and the second outer edge at a distal end of the body;

the body defines a fourth distance between the apex axis and the second outer edge at the plate contacting end; and is

The third distance is less than the fourth distance.

19. The structural assembly of claim 16, wherein the plate mating surface forms a partial oval shape.

20. The structural assembly of claim 16, wherein the tube mating surface includes a third surface portion interconnecting the first and second surface portions, and wherein the third surface portion includes a cross-sectional shape perpendicular to the apex axis, the cross-sectional shape forming an arcuate shape and sized to mate with a rounded corner of the elongated member interconnecting the first and second sidewalls of the elongated member.

Technical Field

The present disclosure relates generally to a gusset structure for distributing stresses at a junction between a panel and an elongate member, and a structural assembly including the gusset structure.

Background

The structural assembly may include an elongated member attached to the plate. Typically, the elongate member is a tubular structure defining a hollow center. The elongated member is attached to the plate around the circumference of the elongated member at a distal end of the elongated member or at an intermediate portion where the elongated member passes through the plate. The elongate member may comprise, for example, four side walls interconnected by four respective corners. Due to the high stiffness of the elongated member in the corner regions of the elongated member, high stress areas are formed in the plate at the locations where the plate is attached to the corners of the elongated member.

Disclosure of Invention

According to one aspect of the present disclosure, a gusset structure is provided. The gusset structure is operable to distribute stresses at the junction formed between the panel and the elongate member over a larger area, thereby reducing the stress level in the panel. The gusset structure includes a body having a plate contacting end forming a plate mating surface and a tube mating surface. The board mating surface is configured to engage the board. The tube mating surface includes a first surface portion and a second surface portion forming an inner surface angle therebetween. The first surface portion and the second surface portion extend away from the plate contact end. The inner surface angle has an apex disposed on an apex axis that intersects the board mating surface. The first surface portion of the tube mating surface is configured to engage the first sidewall of the elongated member. The second surface portion of the tube mating surface is configured to engage the second sidewall of the elongated member.

In one aspect of the gusset structure, the body includes a distal end spaced a length from the plate contacting end along the apex axis. The tube mating surface extends between and interconnects the plate contacting end and the distal end of the body.

In one exemplary embodiment of the gusset structure, the plate mating surface is substantially perpendicular to the apex axis. In other embodiments, the apex axis may be slightly angled relative to the plate mating surface.

In one aspect of the gusset structure, the plate mating surface defines a first region and the distal end forms an end surface defining a second region. The first area of the plate mating surface is larger than the second area of the end surface such that the plate mating surface spreads stress in the plate over a larger area.

In one aspect of the gusset structure, the body includes a cross-sectional area perpendicular to the apex axis. The cross-sectional area of the body increases in size with movement along the apex axis with movement in a direction from the distal end toward the plate contacting end. In one embodiment, the cross-sectional area of the body varies along the apex axis at a variable rate of change per unit length. In another embodiment, the cross-sectional area of the body changes at a constant rate of change per unit length along the apex axis.

In one aspect of the gusset structure, the first surface portion of the tube mating surface defines a first outer edge at an intersection of the first surface portion and the outer surface of the body. The body defines a first distance at the distal end measured between the apex axis and a first outer edge of the body. The body defines a second distance measured between the apex axis and the first outer edge at the plate contacting end. The first distance is less than the second distance. In another aspect of the gusset structure, the second surface portion of the tube mating surface defines a second outer edge at an intersection of the second surface portion and the outer surface of the body. The body defines a third distance between the apex axis and a second outer edge at a distal end of the body. The body defines a fourth distance between the apex axis and a second outer edge at the plate contacting end. The third distance is less than the fourth distance. In an exemplary embodiment, the first distance and the third distance are substantially equal, and the second distance and the fourth distance are substantially equal. Likewise, the plate contact end is larger than the distal end, such that stresses in the plate are spread over a larger area.

In one aspect of the gusset structure, the plate mating surface forms a partially rounded shape. In one exemplary embodiment, the partially rounded shape is a partially elliptical shape. In another exemplary embodiment, the partially rounded shape is a partially circular shape.

In another aspect of the gusset structure, the tube mating surface includes a third surface portion interconnecting the first surface portion and the second surface portion. The third surface portion includes a cross-sectional shape perpendicular to the apex axis, the cross-sectional shape forming an arcuate shape. The arcuate cross-sectional shape of the third surface portion is sized to mate with a rounded corner of the elongated member interconnecting the first and second sidewalls of the elongated member such that the rounded corner of the elongated member nests within an angular pocket formed by the tube mating surface.

In one embodiment of the gusset structure, the body is magnetized such that magnetic forces can temporarily hold the body in place relative to the elongated member and/or the plate before the body is permanently attached to the elongated member and the plate, such as by welding.

In another embodiment of the gusset structure, the body may include a removable handle extending outwardly from the body. The handle may be used as a handset, purchasing assembler or machine to hold the body in place relative to the elongate member and/or the plate while the body is permanently attached thereto, for example by welding.

According to another aspect of the present disclosure, a structural assembly is provided. The structural assembly includes a plate and an elongated member attached to the plate. The elongated member extends along a central longitudinal axis and includes first and second sidewalls disposed adjacent to one another and positioned to form an inner wall angle therebetween. The plate is positioned transverse to a central longitudinal axis of the elongated member. A gusset structure is attached to both the plate and the elongate member. The gusset structure includes a body having a plate contacting end that forms a plate mating surface disposed in abutting engagement with the plate. The body forms a tube mating surface having a first surface portion and a second surface portion. The first surface portion and the second surface portion form an inner surface angle therebetween that is substantially equal to the inner wall angle. Both the first surface portion and the second surface portion extend away from the plate contact end to a distal end of the body. The inner surface angle has an apex disposed on an apex axis that intersects the board mating surface. In an exemplary embodiment, the apex axis is parallel to a central longitudinal axis of the elongated member. A first surface portion of the tube mating surface is disposed against the first sidewall of the elongated member and a second surface portion of the tube mating surface is disposed against the second sidewall of the elongated member. The distal end of the body is spaced a length from the plate contacting end along the apex axis, with the tube mating surface extending between and interconnecting the plate contacting end and the distal end of the body. The plate mating surface defines a first region and the distal end forms an end surface defining a second region. The first area of the plate mating surface is larger than the second area of the end surface.

In one embodiment of the structural assembly, the body of the gusset structure includes a cross-sectional area perpendicular to the apex axis that increases in size with movement along the apex axis in a direction from the distal end toward the plate contacting end.

In one aspect of the structural assembly, the first surface portion of the tube mating surface defines a first outer edge at an intersection of the first surface portion and an outer surface of the body. The body defines a first distance between the apex axis and a first outer edge at a distal end of the body. The body defines a second distance between the apex axis and the first outer edge at the plate contacting end. The first distance is less than the second distance.

In another aspect of the structural assembly, the second surface portion of the tube mating surface defines a second outer edge at an intersection of the second surface portion and the outer surface of the body. The body defines a third distance between the apex axis and a second outer edge at a distal end of the body. The body defines a fourth distance between the apex axis and a second outer edge at the plate contacting end. The third distance is less than the fourth distance.

In one aspect of the structural assembly, the plate mating surfaces of the gusset structure form a partially rounded shape. In one embodiment, the partially rounded shape is a partially elliptical shape. In another embodiment, the partially rounded shape is a partially circular shape.

In another aspect of the structural assembly, the tube mating surface of the gusset structure includes a third surface portion interconnecting the first surface portion and the second surface portion. The third surface portion includes a cross-sectional shape perpendicular to the apex axis, the cross-sectional shape forming an arcuate shape. The arcuate cross-sectional shape of the third surface portion is sized to mate with a rounded corner of the elongated member interconnecting the first and second sidewalls of the elongated member.

The above and other features will become apparent from the following description and the accompanying drawings.

Drawings

The detailed description of the drawings refers to the accompanying drawings.

Fig. 1 is a schematic side view of a vehicle.

FIG. 2 is a schematic perspective view of a structural assembly of the vehicle showing the panel, elongated member and gusset structure attached together.

Figure 3 is a schematic perspective view of a gusset structure from a first perspective.

Figure 4 is a schematic perspective view of the gusset structure from a second perspective.

Fig. 5 is a schematic top view of a structural assembly.

Fig. 6 is a schematic bottom view of the structural assembly.

Fig. 7 is a schematic side plan view of a structural assembly.

Fig. 8 is a schematic cross-sectional view of a structural assembly.

Detailed Description

Those of ordinary skill in the art will recognize that terms such as "above," "below," "upward," "downward," "top," "bottom," and the like are used descriptively in the figures and do not represent limitations on the scope of the disclosure, as defined by the appended claims.

Referring to the drawings, wherein like reference numbers refer to corresponding parts throughout the several views, a vehicle is shown generally at 20 in FIG. 1. The vehicle 20 may include any type of movable platform such as, but not limited to, a tractor, combine, trailer, car, truck, train, or the like. The vehicle 20 includes a structural assembly 22. While the structural assembly 22 is shown incorporated into an exemplary embodiment of the vehicle 20, it should be appreciated that the structural assembly 22 may be incorporated into some other non-movable platform (such as, but not limited to, a building frame or a stationary engine platform). Likewise, while the structural assembly 22 incorporated into the vehicle 20 is described and illustrated in detail, it should be appreciated that the structural assembly 22 need not be a part of the vehicle 20.

Referring to fig. 1, an exemplary embodiment of a vehicle 20 is shown as a combine. The combine harvester includes a stationary frame 24 supporting a head unit 26. Referring to fig. 2, a stationary frame 24 is shown that includes a plurality of structural components 22. Each structural assembly 22 includes an elongated member 28 attached to a plate 30, with a gusset structure 32 attached to and interconnecting the elongated member 28 and the plate 30. It should be appreciated that the use of the structural assembly 22 in the fixed frame 24 of the vehicle 20 is merely an exemplary application of the gusset structure 32. Likewise, the specific details of the vehicle 20 and the fixed frame 24 are not relevant to the teachings of the present disclosure, and therefore are not described in detail herein.

In the exemplary embodiment shown in the figures and described herein, the plate 30, the elongated member 28, and the gusset structure 32 are formed of metal and are welded together to form the structural assembly 22. However, in other embodiments, the plate 30, the elongated members 28, and the gusset structure 32 may be formed of some other non-material (such as, but not limited to, a plastic or nylon material), and may be attached together using some other process suitable for the particular material and application.

The elongated member 28 may comprise a solid or tubular structure defining a hollow center or core. The elongated member 28 extends along a central longitudinal axis 34 and includes a plurality of sidewalls extending parallel to the central longitudinal axis 34. Each of the sidewalls forms a substantially planar outer surface. Each pair of adjacent side walls of the elongate member 28 are connected by a respective corner. The corners of the elongated member 28 may be rounded and include an arcuate cross-section perpendicular to the central longitudinal axis 34. Likewise, each of the corners of the elongated member 28 may be referred to herein as a rounded corner.

In the exemplary embodiments shown in the figures and described herein, and as best shown in fig. 5 and 6, the elongated member 28 includes a rectangular cross-section perpendicular to the central longitudinal axis 34. Likewise, the elongated member 28 may be referred to herein as a rectangular member 28. The rectangular member 28 includes four side walls and four corresponding rounded corners. Each of the corners of the rectangular member 28 form a right angle, i.e. 90 °, connecting their respective side walls. However, other embodiments of the elongated member 28 may include cross-sectional shapes other than the rectangular shapes shown and described herein. Likewise, other embodiments of the elongated member 28 may include more or less than the exemplary four sidewalls and four corners shown in the figures and described herein, wherein each of the corners defines a different angle than the exemplary right angles shown in the figures and described herein.

Referring to fig. 5, the elongated member 28 includes a first sidewall 36, a second sidewall 38, and a corner 40 disposed between and interconnecting the first sidewall 36 and the second sidewall 38. Although the detailed description only describes the first side wall 36, the second side wall 38, and the corner 40 therebetween, it should be understood that the teachings of the present disclosure can be applied to other side walls of the elongated member 28 and their respective corners. The first and second side walls 36, 38 are disposed adjacent to each other and are positioned to form a substantially right angle therebetween.

Referring to fig. 2, plate 30 comprises a flat structure having a thickness and forms a flat outer surface 42 to which elongate member 28 is attached. The elongated member 28 is attached to the plate 30 around the circumference or perimeter of the elongated member 28 at the distal end of the elongated member 28 or at an intermediate portion where the elongated member 28 passes through the plate 30. The plate 30 is positioned transverse to the central longitudinal axis 34 of the elongated member 28 such that the central longitudinal axis 34 and the elongated member 28 intersect the plate 30. The plate 30 may comprise any structure that forms the flat outer surface 42 to which the elongated member 28 is attached, such as a flat plate structure, or a larger wall portion of some other structural member, such as, but not limited to, a tubular structure, a channel structure, an angular structure, an i-beam, and the like.

The gusset structure 32 is attached to and interconnects the plate 30 and the elongate member 28. Due to the cross-sectional geometry of the elongated member 28, the corners 40 of the elongated member 28 exhibit high strength and/or rigidity. The high strength and/or rigidity of the elongated member 28 at the corners 40 may introduce high stresses into the plate 30 when the elongated member 28 is attached to the plate 30. The gusset structure 32 spreads the stresses in the plate 30 over a larger area, thereby reducing the stresses in the plate 30 that would otherwise be concentrated at the junction formed between the plate 30 and the elongated member 28 in the corner 40 connecting the first and second sidewalls 36, 38.

Referring to fig. 3-7, the gusset structure 32 includes a body 44. The body 44 of the gusset structure 32 may be formed by any suitable process (e.g., casting, forging, machining, additive manufacturing, etc.). In the exemplary embodiment described herein, the gusset structure 32 comprises and is formed from a metal. However, in other embodiments, the gusset structure 32 may comprise a non-metal, such as, but not limited to, a plastic or nylon material, and be formed of a non-metal.

The body 44 extends along an apex axis 46 between a plate contact end 48 and a distal end 50. The plate contact end 48 forms a plate mating surface 52 for engagement with the plate 30. In the exemplary embodiment shown in the figures and described herein, the elongated member 28 is positioned in a substantially orthogonal position relative to the plate 30. Likewise, the plate mating surface 52 is substantially perpendicular to the apex axis 46 to position the elongated member 28 in a substantially orthogonal position relative to the plate 30. However, in other embodiments, where the elongate member 28 may be angled at an angle other than ninety degrees relative to the plate 30, the apex axis 46 may likewise be angled at an angle other than ninety degrees relative to the plate 30. Likewise, it should be appreciated that the apex axis 46 may be disposed substantially parallel to the central longitudinal axis 34 of the elongated member 28.

The plate mating surface 52 defines a first region 54 having a perimeter that may form a partially rounded shape. The first region 54 is best shown in fig. 6. The partially rounded shape may include any curved or rounded shape that does not include vertices that may cause local stresses. For example, partially rounded shapes having a shape defining a partial oval or partial ellipse are shown in the figures, with the half-major axis being longer than the half-minor axis. This particular embodiment distributes the stress further away from the joint while excluding any vertices that may cause local stress points in the plate 30. Other embodiments may include a partially rounded shape defining a partially circular shape, wherein the semi-short axis and the semi-long axis are substantially equal. It should be appreciated that the partially rounded shape may include some other shape not shown in the figures or described herein.

As shown in fig. 7, the distal end 50 of the body 44 is spaced a length 56 from the plate contact end 48 along the apex axis 46. As best shown in fig. 3 and 4, the body 44 further defines a tube mating surface 58, the tube mating surface 58 extending between and interconnecting the plate contact end 48 and the distal end 50 of the body 44. The tube mating surface 58 includes a first surface portion 60, a second surface portion 62, and a third surface portion 64, all of which extend away from the plate contact end 48 to the distal end 50 of the body 44. The first surface portion 60 and the second surface portion 62 form an inner surface angle 66 therebetween. The inner surface angle 66 has an apex 68 disposed on the apex axis 46. The value of the inner surface angle 66 is substantially equal to the value of the inner wall angle 70 formed between the first sidewall 36 and the second sidewall 38. In the exemplary embodiment shown in the figures and described herein, the first sidewall 36 and the second sidewall 38 are positioned to form an inner wall angle 70 therebetween that is substantially equal to ninety degrees. Likewise, the exemplary embodiment of the gusset structure 32 includes an inner surface angle 66 between the first surface portion 60 and the second surface portion 62 that is also substantially equal to ninety degrees. It should be appreciated that in other embodiments in which the first and second sidewalls 36, 38 of the elongated member 28 form a non-right angle therebetween having a defined value of greater than or less than ninety degrees, the value of the interior angle between the first and second surface portions 60, 62 is configured to mate and match the defined value. Likewise, it should be appreciated that the inner surface angle 66 may differ from the exemplary right angles shown in the figures and described herein.

A first surface portion 60 of the tube mating surface 58 is positioned to engage the first sidewall 36 of the elongated member 28 and a second surface portion 62 of the tube mating surface 58 is positioned to engage the second sidewall 38 of the elongated member 28. The third surface portion 64 interconnects the first surface portion 60 and the second surface portion 62. The third surface portion 64 includes a cross-sectional shape perpendicular to the apex axis 46 that forms an arcuate shape. The arcuate cross-sectional shape of the third surface portion 64 is sized to mate with the rounded corner 40 of the elongated member 28 interconnecting the first and second sidewalls 36, 38.

As described above, the plate mating surface 52 defines the first region 54. The distal end 50 of the body 44 forms an end surface 72 that defines a second region 74. The second region 74 is best shown in fig. 3. In the exemplary embodiment of the gusset structure 32 shown in the drawings and described herein, the first region 54 of the plate mating surface 52 is larger than the second region 74 of the end surface 72. In other words, the plate contact end 48 is larger than the distal end 50. The gusset structure 32 is configured to include a larger area of the plate mating surface 52 to spread or disperse the internal forces of the plate 30 over a larger area of the plate 30 so as to reduce the internal stresses in the plate 30 formed at the junction between the elongated member 28 and the plate 30 at the corner 40 of the elongated member 28.

Referring to fig. 8, the body 44 of the gusset structure 32 includes or defines a cross-sectional area 100 that is perpendicular to the apex axis 46. The cross-sectional area of the body 44 increases in size with movement along the apex axis 46 in a direction from the distal end 50 toward the plate contact end 48 (as indicated by arrow 76 shown in fig. 7). By doing so, the size of the plate contact end 48 is increased to provide a larger stress dispersion area.

In the exemplary embodiment of the gusset construction 32 shown in the drawings and described herein, the cross-sectional area of the body 44 changes at a variable rate of change per unit length 56 along the apex axis 46. Likewise, when viewed from the side, as shown in fig. 7, the gusset structure 32 includes an outer surface profile 98 connecting the distal end 50 and the plate contacting end 48, the outer surface profile 98 exhibiting a generally concave side profile 98. However, in other embodiments, the cross-sectional area of the body 44 may change at a constant or unchanging rate of change per unit length 56 along the apex axis 46 such that, when viewed from the side, the gusset structure 32 includes an outer surface profile connecting the distal end 50 and the plate contacting end 48 that exhibits a generally triangular side profile.

Referring to fig. 4, the first surface portion 60 of the tube mating surface 58 defines a first outer edge 78 at an intersection of the first surface portion 60 and an outer surface 80 of the body 44. The body 44 defines a first distance 82 between the apex axis 46 and the first outer edge 78 at the distal end 50 of the body 44. The body 44 defines a second distance 84 between the apex axis 46 and the first outer edge 78 at the plate contacting end 48. Because the distal end 50 of the body 44 is smaller than the plate contact end 48, the first distance 82 is smaller than the second distance 84.

Referring to fig. 4, the second surface portion 62 of the tube mating surface 58 defines a second outer edge 86 at the intersection of the second surface portion 62 and the outer surface 80 of the body 44. The body 44 defines a third distance 88 between the apex axis 46 and the second outer edge 86 at the distal end 50 of the body 44. The body 44 defines a fourth distance 90 between the apex axis 46 and the second outer edge 86 at the plate contacting end 48. Because the distal end 50 of the body 44 is smaller than the plate contact end 48, the third distance 88 is smaller than the fourth distance 90.

In the exemplary embodiment shown in the figures and described herein, the first distance 82 and the third distance 88 are substantially equal, and the second distance 84 and the fourth distance 90 are substantially equal. However, in other embodiments, the first distance 82 and the third distance 88 may be different, and the second distance 84 and the fourth distance 90 may be different.

Referring to fig. 8, the plate contact end 48 includes a central axis 92 disposed on the plate mating surface 52. The central axis 92 of the plate contact end 48 extends radially outward from the apex axis 46 and away from the rounded corner 40 of the elongated member 28 toward the periphery of the plate mating surface 52. The central axis 92 bisects the plate mating surface 52 to form two substantially equal halves. In the exemplary embodiment shown in the figures and described herein, the central axis 92 bisects an outer wall angle 94 formed between the first and second sidewalls 36, 38 of the elongate member 28. Likewise, in the exemplary embodiment shown in the figures in which elongate member 28 is rectangular so as to form a right angle between first sidewall 36 and second sidewall 38, outer wall angle 94 is substantially equal to 270 degrees and central axis 92 bisects outer wall angle 94, with a first half of plate mating surface 52 disposed on a first side of central axis 92 and a second half of plate mating surface 52 disposed on a second side of central axis 92.

The components of the structural assembly 22 (i.e., the plate 30, the elongated member 28, and the gusset structure 32) are permanently and fixedly attached together. The components of the structural assembly 22 may be attached together in any suitable manner. For example, the components of the structural assembly 22 may be welded together to form a secure connection therebetween. In other embodiments, other attachment processes (e.g., without limitation, bonding with an adhesive) may be used to connect the components of the structural assembly 22.

To improve assembly efficiency, the body 44 of the gusset assembly may be magnetized such that the magnetic force secures the gusset assembly to the plate 30 and/or the elongated member 28. The magnetic force may secure the gusset assembly in place, allowing the final attachment process to be performed. For example, the magnetic force may hold the gusset assembly in place relative to the plate 30 and/or the elongated member 28 while welding the gusset assembly to the plate 30 and the elongated member 28.

In other embodiments, the gusset structure 32 can be formed to include a removable handle 96 as shown in fig. 3, the removable handle 96 extending outwardly from the body 44. The removable handle may be shaped to provide a convenient hand grip that enables an assembler or robotic machine to easily grasp and hold the gusset plate assembly in place relative to the plate 30 and elongate member 28, allowing the final attachment process to be performed.

While the foregoing describes example embodiments of the present disclosure, these descriptions should not be viewed in a restrictive or limiting sense. Rather, other changes and modifications may be made without departing from the scope and spirit of the disclosure as defined in the appended claims.