Vehicle Frame Bumper Beam Double Attachment Structures
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Solution Overview
Problem
Designing bumper beam attachment structures to effectively address both low speed and high speed crash conditions is challenging, as existing single crush can structures struggle to manage varying energy absorption requirements while minimizing vehicle weight.
Innovation Solution
Implementing a double attachment system with inner and outer attachment structures spaced apart and flanking each other, allowing for efficient load distribution and energy absorption across the bumper beam, including a crush can construction for inner structures and a base plate with a curved portion for outer structures, to handle bending moment loading and provide stable crash performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single crush can attachment structure is used to connect the bumper beam to the front end frame assembly, then the device complexity is reduced, but the ability to address both low speed and high speed crash conditions deteriorates
Solution Approach 1:
The single attachment structure is divided into two separate attachment structures positioned at different locations along the bumper beam. The first attachment structure handles low-speed crash conditions while the second attachment structure addresses high-speed crash conditions, allowing each structure to be optimized for its specific function rather than requiring one structure to handle all conditions.
Solution Approach 2:
Different portions of the bumper beam attachment system are given different properties and functions. The first attachment structure is designed with specific characteristics for low-speed energy absorption, while the second attachment structure has different characteristics optimized for high-speed crash performance, creating local specialization throughout the attachment system.
2Reliability
If larger and more robust attachment structures are used to meet high speed crash requirements, then crash performance improves, but vehicle weight increases
Solution Approach 1:
The crash management function is segmented between two attachment structures of different sizes and strengths. The first attachment structure is sized appropriately for low-speed crashes, while the second attachment structure is designed for high-speed crashes. This segmentation allows the vehicle to meet high-speed crash requirements without requiring both attachment structures to be oversized, thereby controlling overall weight.
Solution Approach 2:
Instead of making all attachment structures excessively robust to handle worst-case scenarios, only the second attachment structure is designed with the strength needed for high-speed crashes. The first attachment structure is optimized for normal low-speed operations, providing partial action sufficient for typical conditions while the second structure provides excessive strength only where needed for severe crashes.
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 double attachment system enhances energy absorption during crashes, reduces weight, and improves the vehicle's crash performance by distributing loads effectively across the frame assembly, ensuring both low speed and high speed energy absorption targets are met.
Implementation Method 1
The attachment structures connecting the bumper beam to the front end frame assembly can each be in the form of a crush can for providing controlled deformation when the bumper beam is impacted by an external force (e.g., a front end collision)
Data Source
AI summary
A frame assembly for a vehicle includes a front end frame assembly extending laterally across the vehicle and disposed adjacent a forward end of the vehicle, and a bumper beam extending laterally across the vehicle and spaced apart longitudinally forward of the front end frame assembly. A first set of spaced apart inner attachment structures connects the bumper beam to the front end frame assembly. A second set of spaced apart outer attachment structures also connects the bumper beam to the front end frame assembly. The second set of outer attachment structures is spaced apart from and flanks the first set of inner attachment structures.