Crash Management System Intermediary Element
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Solution Overview
Problem
Current crash management systems face limitations in absorbing and transferring impact energy effectively, particularly due to stress concentrations at weakened areas such as the connection between the absorber and cross beam, leading to potential failure during collisions.
Innovation Solution
A crash management system design that decouples the cross beam and absorber using an additional hollow profile element, allowing for independent positioning and reducing direct welding, thereby distributing impact energy more evenly and enhancing flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If absorbers are directly connected to the cross beam through welding or screwing, then the structure is simple and manufacturing is easy, but stress concentrations occur at the connection areas leading to potential failure during collisions
Solution Approach 1:
An additional element is introduced as an intermediary component between the absorber and the cross beam. This additional element distributes the crash forces over a larger area, reducing stress concentrations at the connection points while maintaining manufacturing simplicity through standardized connection interfaces.
2Strength
If the cross beam is configured with high bending stiffness to prevent uncontrolled entering, then structural strength is improved, but cracks often occur at the connection between the absorber and the cross beam
Solution Approach 1:
The additional element serves as a stress-distributing intermediary that prevents crack initiation at the cross beam connection area by dispersing concentrated loads, thereby maintaining the high bending stiffness of the cross beam without compromising connection reliability.
Solution Approach 2:
The additional element is pre-installed on the cross beam before absorber attachment, creating a prepared interface that distributes loads before crash forces are applied, preventing crack formation in advance.
3Strength
If absorbers are directly welded to the cross beam, then the connection is strong and device complexity is reduced, but the heat affected zone becomes a weak point limiting development of stiffer solutions
Solution Approach 1:
The additional element acts as a mediator that eliminates direct welding between the absorber and cross beam, removing the heat affected zone weakness while maintaining strong connections through mechanical fastening or bonding interfaces that allow for stiffer design configurations.
4Reliability
If the crash management system is optimized to absorb sufficient crash energy, then safety is improved, but the weight of the vehicle increases which has negative environmental impact
Solution Approach 1:
The additional element is designed with optimized geometry and material properties that enable effective crash energy absorption and distribution while minimizing added weight, achieving a balance between safety performance and environmental impact.
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 design reduces stress on weakened areas, improves energy absorption and transfer, and allows for lighter weight and more flexible system configurations, enhancing safety and compliance with regulatory requirements without increasing vehicle weight.
Implementation Method 1
elements are configured so as to undergo deformation as a result of the impact and thus convert kinetic energy into deformation energy by cold deformation
Data Source
AI summary
A crash management system (1) for a front or rear part of a vehicle having a longitudinal direction X, a transverse direction Y perpendicular to the longitudinal direction X and a vertical direction Z perpendicular to the longitudinal direction X and to the transverse direction Y, said crash management system (1) having a crash management system length (LC) along the Y direction and comprising: a cross beam (2) having a cross beam length (LB) along the Y direction, at least one additional element (3) having an outer face (36) and an inner face (50), wherein the additional element has at least one wall (38) which is connected to said cross beam (2), at least one absorber (4) having an outer face and/or an inner face, characterized in that said cross beam length (LB) is smaller than said crash management system length (LC), said cross beam (2) is connected to said absorber (4) through said additional element (3).