Steel-Reinforced Bumper Beam Assembly With Tolerant Inner Profile
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Solution Overview
Problem
The existing design of bumper beam cross members faces challenges in manufacturing and assembly due to the need for high geometrical tolerance between the outer beam and reinforcement element, which are difficult to achieve with advanced high-strength steel, and limits the optimization of energy absorption capacity.
Innovation Solution
A cross member design where the reinforcement element has a non-matching cross section shape to the outer beam, allowing for separate optimization of each part's shape and manufacturing process, with a M-shaped cross-section for enhanced energy absorption, and a closing plate to ensure assembly precision without costly geometrical tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the reinforcement element has a cross section shape matching the outer beam, then the assembly requires high geometrical tolerance, but this increases manufacturing cost and time due to springback issues with advanced high strength steel
Solution Approach 1:
The patent applies asymmetry by deliberately designing the reinforcement element with a cross-section shape that does not match the outer beam shape. This asymmetric design breaks the requirement for high geometrical tolerance between matching surfaces, allowing standard manufacturing processes for advanced high strength steel without costly springback correction steps.
2Manufacturing precision
If the reinforcement element has a cross section shape matching the outer beam, then assembly requires high geometrical tolerance, but this complicates the assembly process requiring specific precautions
Solution Approach 1:
The asymmetric cross-section design of the reinforcement element relative to the outer beam creates a naturally tolerant fit that does not require precise geometric matching. This simplifies the assembly process by eliminating the need for high strength clamping and other specific precautions that would be required with matching shapes.
3Stability of the object's composition
If the reinforcement element shape matches the outer beam, then the shape is constrained, but this limits optimization of energy absorption capacity
Solution Approach 1:
The patent utilizes asymmetry by designing the reinforcement element with a cross-section shape optimized specifically for energy absorption characteristics, independent of the outer beam shape. This allows the reinforcement element to have geometric features that maximize its energy absorption capacity during impact while not being constrained to match the outer beam's cross-section.
Solution Approach 2:
The patent applies local quality by optimizing the reinforcement element's cross-section shape specifically for the functional requirement of energy absorption in the impact zone, rather than requiring global shape consistency with the outer beam. This localized optimization allows the reinforcement element to have different geometric characteristics tailored to its specific function.
Data Source
AI summary
A cross member (1) for a bumper beam includes an outer beam (2) with a main beam portion (3) comprising an upper beam wall (12), a lower beam wall (14) and a front beam wall (16), defining together a beam inner volume (17) open in a back direction, a reinforcement element (4) defining a reinforced area (24) of the outer beam (2), located inside a part of said beam inner volume (17) and having a cross section, defining a reinforcement inner volume (25) open in the rear direction, a closing plate (6) closing at least a part of the beam inner volume (17). The cross section of the reinforcement element (4) has a shape which is not matching the shape of the outer beam (2) in the reinforced area (24).