Vehicle Front Structure With Crash Box Guide Assembly
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Solution Overview
Problem
Existing vehicle front structures face challenges with variations in processing and assembly accuracy of front side members and crash boxes, leading to misalignment of holes and difficulty in assembly, particularly in battery electric vehicles with longer crash boxes.
Innovation Solution
A front structure design featuring a support member with guide portions that engage with crash boxes to guide them to precise attachment positions, using fiber-reinforced resin for reduced weight and improved strength, and incorporating guide surfaces to restrict relative movement, along with accommodating recessed portions to reduce compressive stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the first upper holes and first lower holes of the bumper reinforcement are made larger than the second upper holes and second lower holes of the crash boxes to accommodate variations in processing and assembly accuracy, then assembly becomes easier, but the position variation of the front ends of the crash boxes with respect to the bumper reinforcement remains large
Solution Approach 1:
The guide portions are provided in advance on the bumper reinforcement at positions that correspond to the front ends of the crash boxes. These guide portions perform the preliminary action of guiding and positioning the crash boxes before the actual attachment process, ensuring accurate positioning despite variations in processing and assembly accuracy.
Solution Approach 2:
The guide portions act as intermediary elements between the bumper reinforcement and the crash boxes. They mediate the positioning process by providing a physical interface that guides the front ends of the crash boxes to the correct positions on the bumper reinforcement, thereby reducing position variation without requiring larger holes.
2Length of moving object
If the lengths in the front-rear direction of the crash boxes are increased for battery electric vehicles, then the structural requirements are met, but the variations in positions of the front ends of the crash boxes with respect to the bumper reinforcement become more remarkable
Solution Approach 1:
The guide portions are pre-positioned on the bumper reinforcement to perform the preliminary function of locating and guiding the front ends of the longer crash boxes. This preliminary positioning action compensates for the increased sensitivity to position variations that arises from the longer crash box lengths in battery electric vehicles.
Solution Approach 2:
The guide portions serve as intermediary structures that decouple the positioning accuracy from the crash box length. By providing a dedicated guiding interface, they ensure that even with longer crash boxes, the position variations at the front ends remain minimal relative to the bumper reinforcement.
Data Source
AI summary
A front structure of a vehicle has a pair of vehicle body frames, a pair of crash boxes, a support member, and a bumper reinforcement. The vehicle body frames are disposed at an interval in a width direction of the vehicle. The crash boxes are located in front of the vehicle body frames to be attached to the vehicle body frames. The support member includes a support body located between the crash boxes, and a pair of extension portions extending outward in the width direction from the support body on both sides. The bumper reinforcement extends in the width direction to be attached to front ends of the crash boxes. The extension portion includes a guide portion which guides the crash box to an attachment position by engaging with the crash box. The guide portion has a surface inclined with respect to a front-rear direction of the vehicle.