Front Crossmember and Bumper Rail Alignment for Sensor Positioning
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Solution Overview
Problem
Achieving consistent gaps and flush fit and finish in vehicle front end alignment is challenging due to the inaccuracy of the vehicle body-in-white, affecting the alignment of exterior panels and ranging sensors.
Innovation Solution
A system comprising a front crossmember and bumper rail with specific fixing points and aligners for precise alignment of the front bumper assembly, headlamp assemblies, and ranging sensors, minimizing the impact of vehicle body misalignments and protecting sensors from damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the ranging sensor is mounted to the front bumper panel, then the sensor is easily accessible and installed, but the sensor position is affected by vehicle body misalignments and panel misalignments leading to inaccurate sensor placement
Solution Approach 1:
The patent extracts the ranging sensor mounting location from the front bumper panel to a separate, more stable structure. The sensor is mounted to a location that is not affected by vehicle body misalignments, such as a dedicated sensor mount or the vehicle body structure itself, thereby separating the sensor positioning system from the misaligned bumper panel while maintaining installation ease through pre-configured mounting points
Solution Approach 2:
The patent introduces an intermediary mounting structure or alignment mechanism between the sensor and the vehicle body. This intermediary component serves as a stable reference that compensates for misalignments in the front bumper panel, ensuring accurate sensor placement while still allowing for relatively easy installation through the intermediary mounting interface
2Ease of operation
If the ranging sensor is mounted to the front bumper panel, then the sensor is readily accessible, but the sensor is vulnerable to damage from low-speed vehicle collisions
Solution Approach 1:
The patent extracts the ranging sensor from the vulnerable front bumper panel location and relocates it to a more protected position on the vehicle body or to a dedicated protected mounting structure. This relocation maintains operational accessibility through appropriate mounting height and positioning while providing inherent protection from low-speed collision damage by placing the sensor away from the primary impact zone
Solution Approach 2:
The patent implements protective measures in advance by positioning the sensor behind protective structures such as the vehicle body panels or by providing dedicated protective housings and mounting locations that absorb or deflect low-speed impact forces before they reach the sensor, thereby cushioning the sensor from damage while maintaining its functional accessibility
3Device complexity
If the vehicle body-in-white is used as the reference for aligning exterior panels, then the alignment process is simplified, but the alignment accuracy deteriorates due to the inaccuracy of the vehicle body
Solution Approach 1:
The patent introduces adjustable alignment fixtures and precision reference structures as intermediary tools between the inaccurate vehicle body-in-white and the exterior panels. These fixtures provide stable, accurate reference surfaces that compensate for vehicle body misalignments, enabling precise panel alignment while maintaining relatively simple alignment procedures through the use of standardized adjustable fixtures
Solution Approach 2:
The patent employs adjustable alignment mechanisms that allow for parameter changes in position, angle, and orientation of the alignment references. By adjusting these parameters, the system can compensate for vehicle body-in-white inaccuracies and achieve precise exterior panel alignment without requiring complete redesign of the alignment process, thus maintaining simplicity while improving accuracy
Data Source
AI summary
There is provided a system (900) and a vehicle (1). The system (900) comprises a front crossmember (810) for the vehicle (1), and a bumper rail (840) for positioning a front bumper assembly (8, 8A) of the vehicle (1). The front crossmember (810) comprises: a first body fixing point (812) securable to a vehicle body (100) of the vehicle (1) at a first lateral side of the vehicle body (100); a second body fixing point (812) securable to the vehicle body (100) at a second lateral side of the vehicle body (100); and bumper rail fixing points (824) configured to receive the bumper rail (840). The bumper rail (840) comprises: bumper assembly positioning points (858A, 858B) for setting a position of the front bumper assembly (8, 8A) in a direction; and a ranging sensor mount (854) to support a ranging sensor (860).