Motor Vehicle Front Structure with Detachable Longitudinal Beam
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Solution Overview
Problem
Current motor vehicle front structures are costly to design and repair due to rigid connections between cross members, which are often damaged in low-speed crashes, requiring expensive repairs.
Innovation Solution
A detachable longitudinal beam is connected to cross members, allowing for adjustable rigidity and easy replacement, with displaceable attachments to prevent vibration transfer and simplify force direction, using adapters and tubular steel for cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the sub-frame is connected to the radiator cross member by means of a hydroformed pipe, then the stability of the front structure is increased, but the design cost becomes very high and the connection is damaged in low-speed crashes requiring expensive repairs
Solution Approach 1:
The front structure is divided into modular components: the longitudinal beam is a separate detachable element connected to cross members via simple attachments, rather than a complex integrated hydroformed pipe structure. This segmentation allows the longitudinal beam to be replaced independently after damage, reducing repair costs while maintaining structural stability through the modular assembly.
2Stability of the object's composition
If the sub-frame is connected to the radiator cross member by means of a hydroformed pipe, then the stability of the front structure is increased, but the repair cost becomes very high after a crash
Solution Approach 1:
The longitudinal beam is designed as a separate replaceable module with simple attachment points to cross members. When damaged in a crash, only the longitudinal beam needs to be replaced rather than repairing complex hydroformed pipe connections, significantly reducing repair costs while maintaining front structure stability through the modular design.
Solution Approach 2:
The longitudinal beam is designed as a sacrificial component that can be easily replaced after damage. The simple attachment design allows the longitudinal beam to be swapped out quickly and inexpensively, while the permanent cross members and attachments retain their value and structural function.
3Ease of repair
If the longitudinal beam is detachably fastened to the cross members, then the ease of replacement is improved, but the rigidity of the connection may be reduced
Solution Approach 1:
The attachment system provides dynamic connectivity: the longitudinal beam is securely fastened to cross members during normal operation to maintain structural rigidity, but can be quickly detached and replaced when damaged. The attachment design balances permanent structural integrity with replaceability, using simple mechanical connections that provide sufficient strength for rated loads while allowing easy removal.
Data Source
AI summary
In the case of a front structure of a motor vehicle two cross members are connected to one another by means of a longitudinal beam. One of the attachments of the longitudinal beam is displaceable by an amount X in the direction of travel and has an adapter made from plastic. During driving operation a transfer of vibrations between the cross members is prevented by means of the attachment. In the event of a crash, the cross member oriented in the direction of travel is supported by the longitudinal beam.