C-Shaped Flange Mounting for Vehicle Control Module Impact Survival
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Solution Overview
Problem
Existing electronic control module mounting systems fail to survive severe side impacts, leading to damage of circuit boards and inoperability, which prevents them from recording collision data, sending distress signals, or cutting off fuel supplies as required by new regulatory standards.
Innovation Solution
A mounting system with C-shaped flanges and crack initiators that allow attachment bolts to slide out or crack during a side impact, reducing housing deformation and protecting electronic components, ensuring the module remains functional and connected for data recording and emergency signaling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the control module housing is rigidly mounted to the vehicle structure, then the module is securely fixed during normal operation, but the housing deforms during severe side impacts, damaging electronic components
Solution Approach 1:
The mounting flange is segmented into two functional zones: a C-shaped opening portion that allows lateral movement and detachment during side impacts, and a bolt engagement portion that provides secure mounting during normal operation. This segmentation enables the flange to differentiate between normal vibrations and severe impact forces, maintaining security when needed while allowing deformation protection when necessary.
Solution Approach 2:
The flange geometry is changed from a conventional closed shape to a C-shaped opening, fundamentally altering its mechanical response to lateral forces. This parameter change enables the flange to transition from a rigid constraint to a controlled detachment mechanism, protecting the housing from deformation during side impacts while maintaining secure mounting during normal operation.
2Reliability
If the control module housing is securely attached to survive normal operation, then the module remains fixed, but attachment bolts cannot release during severe side impacts to prevent housing deformation
Solution Approach 1:
The C-shaped flange is pre-configured with an opening that anticipates lateral impact forces. This preliminary design allows the flange to automatically release attachment bolts when lateral forces exceed normal operating conditions, preventing housing deformation before it can occur during severe side impacts while maintaining secure attachment during normal operation.
3Ease of manufacture
If conventional mounting systems are used, then the module is easy to install, but the module cannot meet new government regulatory requirements for post-collision functionality
Solution Approach 1:
The flange is divided into a C-shaped opening section and a bolt engagement section, creating a simple yet effective mechanism that meets regulatory requirements. This segmented design maintains ease of manufacture and installation while ensuring the module can survive severe side impacts and continue functioning to record collision data and communicate with emergency responders.
Data Source
AI summary
A mounting system for a control module in a vehicle comprises a housing with a flange formed with an opening adapted to receive a fastener for securing the housing to the vehicle. A crack initiator causes a crack to occur in the flange or the housing and thus reduces bending of the housing during a side impact collision causing lateral forces. Preferably, an attachment bolt extends through the opening into the vehicle and the flange forms a C-shape around the opening to allow lateral forces during the side impact collision to force the attachment bolt to slide out of the opening. Preferably, electronic components in the module include an event data recorder for recording data about the vehicle collision and relaying the data after the collision, a communications system for calling for assistance and a controller for cutting off the vehicle fuel supply.