Crossbeam Reinforcement Structure for Pole Crash Integrity
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Solution Overview
Problem
Existing crash management systems for vehicles, particularly in electric vehicles, fail to prevent crossbeams from tearing apart during collisions with pole-type obstacles, which can compromise passenger safety by allowing the obstacle to penetrate the passenger compartment.
Innovation Solution
A reinforcing element with strategically placed recesses, such as slots or holes, is integrated into the crossbeam, aligned centrally with the crossbeam's center plane, providing a form-fit or clamping-fit connection, and made of extruded aluminum or aluminum alloy, to enhance structural integrity and absorb impact loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional crossbeam structure is used without additional reinforcement, then the device complexity is low and manufacturing is simple, but the crossbeam tears apart during collisions with pole-type obstacles
Solution Approach 1:
The reinforcing element is divided into multiple segments or sections along its length, with each section providing localized reinforcement at critical stress points. This segmentation allows the structure to maintain overall integrity while distributing the reinforcement function across multiple discrete elements, preventing the crossbeam from tearing apart during pole collisions.
Solution Approach 2:
The crossbeam system combines the base crossbeam structure with an additional reinforcing element made of high-strength material. This composite construction integrates two different structural components - the original crossbeam and the inserted reinforcing element - to achieve superior strength and collision resistance while maintaining manufacturability through separate production and assembly.
2Reliability
If the total surface of recesses in the front wall is between 1% and 70% of the front wall surface, then the reinforcing element achieves optimized effect at different impact points, but the manufacturing process becomes more complex
Solution Approach 1:
The front wall of the reinforcing element features recesses with specific surface area proportions (1%-70%) strategically positioned to provide localized reinforcement where impact forces are most likely to occur. This local quality enhancement ensures optimized impact resistance at critical areas without requiring complete reinforcement of the entire surface, balancing reliability with manufacturability.
3Strength
If multiple recesses are provided in the reinforcing element, then the structural integrity is enhanced for various impact scenarios, but the manufacturing time and cost increase
Solution Approach 1:
The reinforcing element incorporates multiple recesses providing partial reinforcement at key locations rather than complete reinforcement throughout. This partial action approach achieves sufficient structural integrity for various impact scenarios while limiting the manufacturing complexity and time required, as the recesses are concentrated in specific areas rather than distributed uniformly across the entire structure.
Data Source
AI summary
The invention relates to a crash management system (100) for a motor vehicle, the crash management system (100) comprising a crossbeam (10; 10a; 10b) for being connected to a body shell structure of the motor vehicle, the crossbeam (10; 10a; 10b) comprising a front flange (32), a rear flange (28), and at least two transverse flanges (29, 30) connecting the front flange (32) to the rear flange (28), said flanges forming a closed cross section of the crossbeam (10; 10a; 10b), and the crash management system (100) comprising a reinforcing element (20; 20a to 20f) disposed in the cross section of the crossbeam (10; 10a; 10b) and having multiple oblong recesses (48; 48h; 48i; 48j) in a front wall (38; 38f; 38h; 38i; 38j) of the reinforcing element (20; 20a to 20f) on the side facing the front flange (32) of the crossbeam (10; 10a; 10b).