Vehicle Bonnet Hinge with Integrated Pyrotechnic Release Unit
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Solution Overview
Problem
The existing bonnet hinge mechanisms for deployable bonnet systems in vehicles face challenges during manufacturing and assembly, particularly in the A-shop and B-shop, due to electro-deposited coating and paint processes, leading to quality risks such as damage to paint and coating layers, incorrect assembly, and geometry issues, when transport pistons are exchanged for release units in the C-shop.
Innovation Solution
A bonnet hinge mechanism with a releasable hinge piston that allows for lifting of the bonnet during production, where the hinge piston is integrated and remains in place, enabling all production activities in the A-shop, B-shop, and C-shop, and includes a pyrotechnically activated release unit for lifting the bonnet upon impact detection, ensuring the piston's secure interface and dislodging mechanism for activation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If transport pistons are exchanged for release units in the C-shop, then the release system can be assembled, but paint damage and coating integrity are compromised
Solution Approach 1:
The release unit is pre-assembled with the hinge piston before the A-shop painting process. This preliminary assembly eliminates the need for later exchange operations in the C-shop that would compromise paint integrity. The hinge piston remains in place throughout painting, coating, and assembly processes, ensuring continuous protection of paint and coating layers.
2Ease of manufacture
If transport pistons are exchanged for release units in the C-shop, then the release system can be assembled, but assembly errors and geometry issues occur
Solution Approach 1:
The release unit is pre-assembled with the hinge piston before painting and coating processes. This preliminary assembly ensures correct geometry and positioning are established early, eliminating later assembly errors. The integrated unit maintains precise alignment throughout all subsequent manufacturing stages.
Solution Approach 2:
The release unit and hinge piston are merged into a single integrated assembly. This combination eliminates separate assembly operations that could introduce errors, ensuring consistent geometry and reducing the risk of misalignment between components.
3Object-affected harmful factors
If transport pistons are used during painting, then paint integrity is maintained, but additional assembly steps and inventory complexity are required
Solution Approach 1:
The release unit and hinge piston are merged into a single integrated assembly that remains in place throughout painting and coating. This eliminates the need for separate transport pistons and subsequent exchange operations, reducing assembly process complexity while maintaining paint integrity.
Solution Approach 2:
The integrated release unit serves multiple functions: it acts as the hinge piston during painting and coating, and later functions as the release mechanism for pedestrian impact scenarios. This multi-functionality eliminates the need for separate components and reduces inventory requirements.
4Adaptability or versatility
If multiple body variants are produced, then different vehicle configurations are available, but production efficiency and quality assurance decrease
Solution Approach 1:
The integrated release unit with hinge piston serves as a universal component for all vehicle body variants. Whether the vehicle requires deployable bonnet functionality or not, the same integrated unit can be installed, eliminating the need for different hinge configurations and simplifying production across all vehicle models.
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 solution eliminates risks of paint damage, incorrect assembly, and geometry issues, reduces production and assembly time, and allows for a single bonnet hinge mechanism variety, enhancing quality assurance and reducing inventory needs by maintaining the piston's integrity throughout the production and service life.
Implementation Method 1
a pyrotechnically activated device for providing an activation force to the integrated release bolt in order move the integrated release bolt from the locking position to the unlocking position
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
The present invention relates a bonnet hinge mechanism (1) for a deployable bonnet system in a vehicle allowing for lifting of the bonnet to increase deformation distance to engine bay components in case of a detected or predicted impact with a pedestrian and a method for provision thereof. The bonnet hinge comprises at least two members (2, 3) for effecting the lifting through relative pivotational movement. The members (2, 3) are pivotally secured to each other and interconnected by a releasable hinge piston (4) which inhibits relative pivotational motion between the members (2, 3). The hinge piston (4), at a first end (4a), has an interface for receiving a release unit (5) for releasing the hinge piston (4) such that relative pivotational motion between the members (2, 3) for effecting lifting of the bonnet is allowed.