Transverse Crash Strut Layout for HV Component Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional underrun protection devices and energy dissipation techniques fail to adequately protect high-voltage components in commercial vehicles, particularly battery packs, from damage and fire risks during collisions with trailers, as these components are not adequately shielded in the area above the vehicle's frame longitudinal members.
Innovation Solution
A deformation device is attached to the vehicle's frame longitudinal members, extending above and transversely to absorb impact energy through crash struts and receiving elements, specifically designed to protect high-voltage components by dissipating energy and reducing impact forces during collisions, featuring curved, hollow, and strategically positioned struts for enhanced deformation properties and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional underrun protection devices are used, then the area below the frame longitudinal members is protected, but the area above the frame longitudinal members where HV components are located is not adequately protected
Solution Approach 1:
The protection device is segmented into multiple receiving elements (first receiving element, second receiving element, third receiving element) that are distributed at different heights above the frame longitudinal members. Each receiving element targets a specific height range that trailers may penetrate during a crash, providing zone-based protection for HV components without requiring a single complex monolithic structure.
Solution Approach 2:
The protection device extends in the vertical dimension (height) above the frame longitudinal members, rather than only horizontally as in conventional underrun protection. By placing receiving elements at different heights (first, second, and third receiving elements), the device protects against trailers of varying heights that would otherwise penetrate into the HV component area.
2Reliability
If the deformation device extends above the frame longitudinal members to protect HV components, then protection coverage is improved, but the device complexity increases
Solution Approach 1:
The deformation device is divided into multiple independent receiving elements positioned at different heights. Each receiving element can be a simple deformation component that absorbs impact energy, and they work together as a system to provide comprehensive protection across different vertical zones without requiring each individual component to be overly complex.
Solution Approach 2:
The receiving elements serve multiple functions: they act as deformation devices to absorb impact energy, serve as mounting structures for HV components, and provide protection across different height zones. This multi-functionality reduces the need for separate dedicated structures for each purpose, thereby managing complexity while improving protection coverage.
3Reliability
If multiple receiving elements are used to protect against different trailer heights, then protection effectiveness is improved, but the manufacturing complexity increases
Solution Approach 1:
The protection device is segmented into multiple receiving elements that can be manufactured as separate, standardized components. Each receiving element can be produced using the same manufacturing process and then assembled in different height configurations, simplifying production while allowing customization for different protection height requirements.
Solution Approach 2:
The receiving elements can be manufactured with adjustable parameters such as height, spacing, and deformation characteristics. By changing these parameters rather than redesigning the entire structure, the device can be adapted to protect against different trailer heights while maintaining ease of manufacture through standardized component design and assembly procedures.
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
The deformation device effectively reduces impact forces and protects high-voltage components from damage and fire risks by absorbing and redirecting energy, ensuring the safety of the driver and the vehicle's electrical systems during collisions with trailers.
Implementation Method 1
a deformation device (10) which can be deformed in the event of a crash, thereby reducing impact forces
Implementation Method 2
designed to be deformable in the event of a crash, dissipating impact forces or impact energy
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to an arrangement for energy degradation in the event of energy acting on a utility vehicle as a result of a crash. The invention also relates to a utility vehicle having such an arrangement. The arrangement (6) comprises a deformation device (10) which is deformable with the degradation of impact forces in a crash situation, and also a first receiving element (20) and a second receiving element (20) for fastening the deformation device (10) to the two frame longitudinal members (3) of the utility vehicle (1). The deformation device (10) is connected at a first end region (10a) to the first receiving element (20) and at an opposite, second end region (10b) to the second receiving element (20). Here, the first receiving element (20) and the second receiving element (20) are configured in such a way that the first receiving element (20) and the second receiving element can each be fastened to one of the frame longitudinal members. Furthermore, the deformation device (10) and the first and second receiving element (20) are designed in such a way that, when the receiving elements (10) are each fastened to the frame longitudinal members (3), the deformation device (10) extends above, and transversely with respect to, the frame longitudinal members (3). The deformation device can have one or more tubular crash struts (11). The thus arranged deformation device (10) particularly offers protection for a component, for example a high-voltage component, arranged between the frame longitudinal members in the event of the utility vehicle colliding as a result of a crash with a trailer travelling in front.