Bumper Towing Receptacle Segmentation for Crash Integrity
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Solution Overview
Problem
Current bumper systems face a conflict between achieving high crash performance, cost-effectiveness, and integrating towing eyes without compromising crash management systems or design requirements, particularly due to the use of lightweight materials and the need for steel towing eyes to handle high forces.
Innovation Solution
A bumper arrangement featuring a cross member with crash boxes coupled to a side member, incorporating a detachable towing device receptacle with a flange plate and threaded sleeve, made entirely of steel for high tensile strength, and a modular design that integrates with crash management systems without affecting crash performance, using a cohesive coupling method like welding for anti-corrosion protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel towing eyes are used to handle high towing forces, then towing strength is improved, but vehicle weight increases
Solution Approach 1:
The towing eye system is segmented into multiple components: a mounting bracket attached to the bumper beam, a separate towing eye, and a connecting element. This allows the heavy steel towing eye to be detached and stored when not in use, while the mounting bracket provides structural support integrated into the bumper system.
Solution Approach 2:
The towing eye is extracted as a detachable component from the permanent vehicle structure. It can be removed and stored in a storage compartment when not needed, eliminating the need for a permanent heavy steel component that would increase vehicle weight throughout its entire service life.
2Adaptability or versatility
If towing eyes are integrated into crash management systems, then towing functionality is improved, but crash performance deteriorates
Solution Approach 1:
The towing system is segmented into a mounting bracket that interfaces with the bumper beam (separate from crash management components) and a detachable towing eye. This separation ensures that the towing functionality does not interfere with the crash management system's integrity and performance.
Solution Approach 2:
The mounting bracket acts as an intermediary component between the bumper beam and the towing eye. It provides a dedicated attachment point that does not compromise the crash management system, allowing towing forces to be transmitted through the bracket rather than directly through crash management components.
3Ease of manufacture
If simple steel screw-in eyes are used for towing, then cost is reduced, but integration with modern crash management systems deteriorates
Solution Approach 1:
The towing system is divided into a mounting bracket that integrates with the bumper assembly and a separate towing eye component. This segmentation allows the bracket to be designed specifically for integration with modern bumper and crash management systems, while the towing eye itself remains a simple, cost-effective steel component.
Solution Approach 2:
The mounting bracket serves multiple functions: it provides structural support for the towing eye, integrates with the bumper beam assembly, and can be designed to work with various towing eye types. This multi-functionality enables cost-effective simple components to be integrated into complex modern vehicle systems.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The arrangement has a cross beam at which crash box is coupled, and a retainer (1) provided for a releasably linked towing hook. The retainer has a flange plate (2) and a hole element (3) for retaining the towing hook, where the flange plate is coupled at the crash box. The flange plate is coupled between the crash box and a longitudinal beam by a fastening bolt. The retainer is made of tempered steel. The hole element has a hollow section that is coupled indirectly or directly with a threaded sleeve (4).