Crash Crossbeam Attachment Layout for Vertical Position Tolerance
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Solution Overview
Problem
Existing crash management systems for motor vehicle front or rear areas face challenges in adjusting the vertical position of crossbeams laterally, particularly in simple and efficient ways, while maintaining good crash properties.
Innovation Solution
The system employs extruded attachment adapters with a transverse extrusion direction, allowing the crossbeam to project over two attachment adapters in the transverse direction, and utilizes stop areas and welds to define and secure the crossbeam's vertical position, ensuring a strong and stable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the attachment adapter is designed with extrusion direction in the vertical direction to adjust crossbeam position, then the vertical position adjustment is achieved, but the device complexity increases and installation becomes more difficult
Solution Approach 1:
The patent inverts the conventional design by changing the extrusion direction from vertical to transverse. This inversion simplifies the attachment adapter structure while maintaining the ability to adjust crossbeam position, as the transverse extrusion allows the crossbeam to project laterally over the adapters rather than requiring vertical adjustment mechanisms
Solution Approach 2:
The patent transitions from vertical dimension adjustment to transverse dimension adjustment. By extruding the attachment adapter in the transverse direction and allowing the crossbeam to project laterally, the position adjustment is achieved through a different spatial dimension, simplifying the overall structure
2Reliability
If the crossbeam is positioned to project over the crash box end face in the vertical direction, then crash management is achieved, but the connection surface area is limited and stress concentrations occur
Solution Approach 1:
The patent extends the connection interface from a limited vertical end-face contact to a larger transverse projection area. The crossbeam projecting laterally over the attachment adapters creates an extended connection surface in the transverse dimension, distributing stresses more effectively while maintaining crash management capabilities
3Ease of manufacture
If traditional attachment methods are used without lateral projection, then installation is simpler, but the crossbeam cannot accommodate structural tolerances in the vertical direction
Solution Approach 1:
The patent changes the geometric parameters of the attachment system by introducing lateral projection. This parameter change allows the crossbeam to extend beyond the attachment adapters in the transverse direction, creating a tolerance buffer that accommodates vertical structural variations while maintaining straightforward installation procedures
Data Source
Figure 1~3
AI summary
The invention relates to a crash management system (100) for a front or rear area of a motor vehicle having a longitudinal direction (X), a transverse direction (Y) running perpendicular to the longitudinal direction (X), and a vertical direction (Z) running perpendicular to the longitudinal direction (X) and the transverse direction (Y), the crash management system (100) comprising a crossbeam (10) extending essentially in the transverse direction (Y), the crossbeam (10) being configured to be attached to a vehicle structure by means of two crash boxes (12), which are disposed at a distance (a) from each other, and an attachment adapter (25; 25a; 25b) for attaching the crossbeam (10) to the crash box (12), the attachment adapter (25; 25a; 25b) being associated with one crash box (12) and the crossbeam (10) and connected to the crash box (12), the attachment adapter (25; 25a; 25b) being an extruded component, and the crossbeam (10) projecting over the cross section of the crash box (12) on one side on an end face (28) of the crash box (12) facing the crossbeam (10) when viewed in the vertical direction (Z).