Lower Control Arm Break-Away Mount for Small Overlap Crashes
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Solution Overview
Problem
Current vehicle designs fail to effectively manage lateral loads during small overlap collisions, leading to potential damage and intrusion into the occupant compartment, as they do not adequately distribute kinetic energy laterally to reduce impact forces.
Innovation Solution
The implementation of a crossmember and deformable structures that apply lateral forces to displace the vehicle during a collision, combined with break-away regions in the lower control arm and a deflector system to direct the wheel away from the occupant compartment, effectively managing wheel kinematics and reducing intrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the lower control arm is rigidly connected to the frame member, then structural strength is improved, but wheel kinematics control during collision deteriorates
Solution Approach 1:
The lower control arm connection is divided into two distinct regions: a rigid rear connection to the frame member for structural strength, and a break-away front connection that can separate during collision to enable wheel pullout and kinematic control. This segmentation allows each region to fulfill its specific function independently.
Solution Approach 2:
The front mount connection is designed with dynamic characteristics, transitioning from a constrained rigid state during normal operation to a separated state during collision. The break-away region enables this dynamic transition, allowing the system to adapt its connectivity based on collision conditions.
2Reliability
If deformable structures are added to apply lateral forces, then crashworthiness is improved, but device complexity increases
Solution Approach 1:
The deformable structure integrates multiple functions into a single component: it provides lateral force application through controlled deformation, serves as a load path for crash forces, and works in conjunction with the crossmember to achieve vehicle lateral displacement. This merging reduces the need for separate dedicated components.
Solution Approach 2:
The deformable structure utilizes controlled changes in its structural parameters (deformation, shape change) during collision to generate the desired lateral force. By changing its physical state from rigid to deformed, the structure activates the lateral force mechanism without requiring additional active components.
3Force
If the crossmember is rigidly affixed to longitudinal frame members, then lateral load transmission is improved, but energy absorption deteriorates
Solution Approach 1:
The load path is segmented into rigid connections (crossmember to frame members) for efficient lateral force transmission and deformable regions (deformable structure, break-away mount) for energy absorption. This segmentation allows simultaneous optimization of both force transmission and energy dissipation.
Solution Approach 2:
The deformable structure converts the harmful effect of rigid load transmission into beneficial energy absorption through controlled deformation. The structure that could potentially transmit excessive forces is instead designed to deform in a controlled manner, dissipating energy while still maintaining load path integrity.
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
This solution enhances the vehicle's crashworthiness by laterally displacing the vehicle and directing the wheel away from the occupant compartment, reducing damage and intrusion during small overlap collisions, thereby minimizing the impact on occupants.
Implementation Method 1
The deformable structure is affixed to one lateral side of the vehicle, arranged longitudinally forward of the crossmember, arranged laterally outside of the first frame member, and configured to deform during a small overlap collision. While deforming, the structure applies a lateral force on a first end of the crossmember to cause lateral displacement of the vehicle.
Implementation Method 2
The second face is configured to deflect towards the first face under the small overlap collision. For example, the wedge may deform to form a substantially sharper wedge angle, thus elongating in the longitudinal direction.
Data Source
AI summary
A system for managing wheel kinematics during a collision event includes a break-away region for releasing a joint of a lower control arm. The system includes a recess arranged in a frame member, and a pin arranged vertically in the recess and configured to couple the lower control arm to the frame member. The break away region includes a reduced stiffness and is configured to fail under the collision event to allow the pin to move laterally out of the recess. The recess may be formed by a top plate and a bottom plate or a C-shaped bracket, which include through features to accommodate the pin. The break-away region includes a first notch and a second notch that reduce a stiffness of the structures that form the recess, thus allowing the pin to be released under a predetermined loading. The break-away region may fracture to release the pin.