One-Piece Crash Member Extrusion for Weld-Free Energy Absorption
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Solution Overview
Problem
Existing crash management systems in vehicles face issues with weakened connections due to welding seams and high local heat input, which can lead to instability and inefficient energy absorption, particularly in high-mass vehicles like battery electric vehicles.
Innovation Solution
A crash management system comprising a cross member and crash absorbing components made from a single extruded profile, eliminating the need for welding by forming the components in one piece and ensuring stable connections through bending and pre-cutting processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If crash absorbing components are welded to the cross member, then connection is achieved, but local heat input increases and material rigidity decreases
Solution Approach 1:
The crash absorbing components and cross member are merged into a single monolithic structure made from one extruded profile, eliminating the need for welding connections and thereby avoiding local heat input that would compromise material rigidity
Solution Approach 2:
The single extruded profile is segmented into functional zones during the extrusion process, creating distinct crash absorbing components and cross member sections that are structurally integrated but functionally differentiated, avoiding post-extrusion joining operations
2Strength
If crash absorbing components are welded to the cross member, then connection is achieved, but welding seams create weakness points under impact stress
Solution Approach 1:
The crash absorbing components and cross member are merged into a single monolithic structure made from one extruded profile, eliminating the need for welding connections and thereby avoiding local heat input that would compromise material rigidity
Solution Approach 2:
The welding operation and associated welding seams are completely extracted from the construction process, removing the source of weakness points that would otherwise exist at connection interfaces between crash absorbing components and cross member
3Ease of manufacture
If separate manufacturing of crash absorbing components and cross member is performed, then production flexibility is maintained, but production costs increase
Solution Approach 1:
The crash absorbing components and cross member are merged into a single monolithic structure made from one extruded profile, eliminating the need for welding connections and thereby avoiding local heat input that would compromise material rigidity
Solution Approach 2:
The single extruded profile serves multiple functions simultaneously - it forms both the crash absorbing components and the cross member, integrating what would traditionally require separate manufacturing processes into one universal production method
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 enhances stability and energy absorption capacity while reducing production costs and simplifying manufacturing, ensuring even distribution of impact energy and improved rigidity.
Implementation Method 1
The cross member transfers the energy resorting from an impact into the two crash absorbing components, where the impact energy is predominately converted into deformation work
Data Source
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AI summary
The present invention relates to a crash management system (1) for a vehicle comprising a cross member (2) and two crash absorbing components (3), wherein the cross member (2) and the two crash absorbing components (3) are made from a single extruded profile (21) which comprises at least two profile chambers (4, 5, 6, 7, 8) which extend in longitudinal direction (R) of the single extruded profile (21). The invention further relates to a method for producing such a crash management system (1).