Bumper Bracket with Cantilever Elements
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Solution Overview
Problem
Existing bumpers face challenges in achieving a balance between low weight, high dimensional stability, and efficient energy absorption while maintaining simple production and handling, with existing solutions often requiring complex designs and high side member forces.
Innovation Solution
A bumper design featuring a multi-chamber profile with cantilever elements and a hollow profile carrier section that includes a central chamber and outer chambers, with insert openings and tubular channels for efficient energy absorption, allowing for detachable connection to side members using screws.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a lightweight bumper structure is used, then weight is reduced, but dimensional stability and energy absorption capacity deteriorate
Solution Approach 1:
The bracket is divided into a hollow profile carrier section with multiple chambers (central chamber and outer chambers) and plate-like cantilever elements. This segmentation creates a lightweight structure that maintains dimensional stability through the multi-chamber design while reducing overall weight compared to solid structures.
Solution Approach 2:
The bracket combines a hollow profile carrier section with plate-like cantilever elements to create a composite structure. This composite design achieves both weight reduction and maintained dimensional stability by strategically placing structural elements where needed while leaving other areas hollow or open.
2Loss of energy
If a complex bracket design is used to improve energy absorption, then energy absorption capacity is improved, but device complexity and production difficulty increase
Solution Approach 1:
The plate-like cantilever elements are designed to deform dynamically during impact, absorbing energy through controlled deformation. This dynamic behavior allows the bracket to absorb impact energy efficiently while maintaining a relatively simple static structure that is easy to manufacture.
Solution Approach 2:
The bracket is segmented into a hollow profile carrier section and separate plate-like cantilever elements that can be produced independently and then assembled. This segmentation simplifies production by allowing each component to be manufactured separately using standard processes, then joined together to form the complete energy-absorbing structure.
3Loss of energy
If conventional bracket designs are used, then production is maintained, but side member forces are high and energy absorption is inefficient
Solution Approach 1:
The plate-like cantilever elements are designed to deform dynamically during impact, absorbing energy through controlled deformation. This dynamic behavior allows the bracket to absorb impact energy efficiently while maintaining a relatively simple static structure that is easy to manufacture.
Solution Approach 2:
The bracket design changes the mechanical parameters of the connection system by introducing a hollow profile carrier section with specific chamber configurations and plate-like cantilever elements. These parameter changes optimize the force distribution and energy absorption characteristics, reducing side member forces while improving overall energy absorption efficiency.
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 design achieves efficient energy absorption with reduced side member forces, improved dimensional stability, and simplified production and handling, while maintaining a lightweight structure.
Implementation Method 1
the design of the connection to the vehicle side member also influences its shape retention and its ability to compensate for the deformation energy that occurs
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A bumper (10) with brackets (46) to be attached to it for fastening to longitudinal members (30) of a vehicle consists of profile walls (14, 16) arranged at a distance from each other as a compression strap and tension strap, respectively, and a pair of connecting flank walls (18) forming a hollow profile (12). The bracket (46) is designed as a hollow profile with at least one side wall and two transverse walls adjoining it, with a hollow profile support section associated with a longitudinal member (30). The latter is adapted to the inner cross-section of the longitudinal member (30) as a plug-in section, and the other end region of the bracket (46) is provided with cantilever elements projecting from its front edge, which are directed approximately parallel to the transverse walls. In the operating position, the cantilever elements of the bracket (46) are associated with the flank walls (18) of the bumper (10) and detachably connected to it; the bumper (10) is bolted to the cantilever elements of the bracket (46).