Collapsible Fairlead Mounting Bracket for Winch Impact Compliance
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Solution Overview
Problem
The presence of rigid winch hooks and fairlead devices in vehicles can affect impact test results and airbag sensor calibrations, necessitating duplicative and expensive impact testing and manufacturing packages.
Innovation Solution
A collapsible or crushable mounting bracket assembly is integrated with the fairlead device, allowing it to deflect into the bumper structure during an impact event, reducing resistance and minimizing the impact of the winch hook and fairlead device on impact testing and sensor calibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid fairlead device and hook are used for the winch assembly, then the structural strength and reliability are improved, but the impact test results and airbag sensor calibrations are affected, requiring duplicative and expensive impact testing
Solution Approach 1:
The mounting bracket assembly is segmented into a rigid portion (for structural support) and a collapsible portion (for impact absorption). This segmentation allows the system to maintain structural reliability during normal operation while enabling controlled deformation during impact events, thereby eliminating the need for duplicative impact testing.
Solution Approach 2:
The mounting bracket assembly changes its structural parameter from rigid to collapsible during impact events. The collapsible portion is designed to deform at controlled force levels, transforming the bracket from a rigid obstacle that affects sensor calibration to a compliant structure that allows hooks to deflect without significantly affecting impact test results or airbag sensor calibrations.
2Strength
If a rigid mounting bracket is used to secure the fairlead device, then the mounting strength is improved, but the force required during impact events increases, affecting sensor readings
Solution Approach 1:
The mounting bracket is divided into rigid and collapsible portions. The rigid portion maintains mounting strength for securing the fairlead device during normal operation, while the collapsible portion reduces impact force during collision events by deforming in a controlled manner, preventing excessive force from being transmitted to the vehicle structure and sensors.
Solution Approach 2:
The collapsible portion of the mounting bracket acts as a pre-designed cushioning element that activates during impact events. This beforehand cushioning mechanism absorbs impact energy through controlled deformation, reducing the peak force transmitted to the vehicle structure and ensuring that hook deflection does not significantly affect sensor readings.
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 solution enables the winch hook and fairlead device to be deflected out of the way without significant force or deceleration, thus not affecting impact test results or airbag sensor calibrations, eliminating the need for duplicative and expensive testing and manufacturing packages.
Implementation Method 1
the frame structure and the mounting surface are adapted to be collapsed or crushed towards the bumper structure when a sufficient force is applied to the fairlead device by a hook of the winch assembly
Data Source
AI summary
A mounting bracket assembly for a vehicle, including: a mounting surface adapted to receive a fairlead device for a winch assembly of the vehicle; and a frame structure coupled to the mounting surface and adapted to be secured to a bumper structure of the vehicle; wherein the frame structure and the mounting surface are adapted to be collapsed or crushed towards the bumper structure when a sufficient force is applied to the fairlead device by a hook of the winch assembly when the hook is impacted during an impact event. The fairlead device and the hook are deflected into an opening formed in a front member of a bumper assembly with the hook being at least flush with an exterior surface of the front member of the bumper assembly.