Vehicle Door Cable Reinforcement for Side Impact Force Distribution
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Solution Overview
Problem
Current vehicle crash tests, such as side impact tests, face challenges in effectively distributing and managing forces to prevent door intrusion and occupant injury, particularly in B-pillarless vehicle configurations where traditional reinforcement methods may not adequately address the structural integrity and kinematic control during impacts.
Innovation Solution
A vehicle system featuring a cable reinforcement mechanism with rotational actuators and moveable pulleys that tension and deploy a cable across pillars to distribute impact forces, utilizing electric motors or pyrotechnic charges for actuation, and a control system to manage the cable's tension based on impact detection, thereby enhancing door reinforcement and occupant safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional reinforcement methods are used in B-pillarless vehicle configurations, then manufacturing simplicity is maintained, but structural integrity and door intrusion prevention are insufficient
Solution Approach 1:
The patent employs a dynamic cable reinforcement system where cables can be tensioned or relaxed based on impact conditions. The cables are configured to be tensioned during side impacts to provide reinforcement, and relaxed during normal operation to avoid interference with door functionality. This dynamic adjustment allows the system to provide strength when needed while maintaining ease of manufacture and operation during normal conditions.
Solution Approach 2:
The patent changes the physical state and tension parameters of the cable reinforcement system based on operational conditions. During side impacts, the cables are tensioned to their optimal load-bearing capacity to prevent door intrusion. During normal operation, the tension is reduced or released to eliminate interference with door opening and closing operations. This parameter adjustment resolves the contradiction between providing structural integrity and maintaining manufacturing simplicity.
2Strength
If cables are tensioned continuously to maintain door reinforcement, then structural integrity is improved, but ease of operation and energy consumption increase
Solution Approach 1:
The cable reinforcement system is designed to dynamically adjust its tension state based on operational requirements. During normal door operation, the cables are relaxed or released to allow smooth opening and closing without resistance. During detected side impacts, the system rapidly tensions the cables to provide reinforcement. This dynamic switching between tensioned and relaxed states resolves the contradiction between maintaining door reinforcement and ensuring ease of operation.
Solution Approach 2:
The cable tensioning operation occurs periodically or event-driven rather than continuously. The system monitors for impact conditions and only tensions the cables when side impacts are detected. Between impact events, the cables remain relaxed to avoid interfering with normal door operations. This periodic activation pattern eliminates continuous energy consumption and operational interference while maintaining protection when needed.
3Reliability
If cable tension is maintained during normal operation, then door intrusion prevention is ready, but energy consumption and operational interference increase
Solution Approach 1:
The cable tensioning system operates periodically or event-driven rather than continuously. Impact detection sensors monitor for side impact conditions and trigger cable tensioning only when needed. During normal operation between impact events, the cables remain relaxed and actuators are inactive, eliminating continuous energy consumption. This periodic activation maintains protection readiness while minimizing energy use.
Solution Approach 2:
The system performs preliminary impact detection and prepares the cable reinforcement system in advance of actual impact. Sensors detect potential side impact conditions and pre-tension the cables before the full impact force is applied. This preliminary action ensures immediate protection readiness without requiring continuous tensioning, as the system can rapidly transition from relaxed to tensioned state when impacts are anticipated.
4Adaptability or versatility
If complex actuation systems are used to control cable tension, then adaptability to impact conditions is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The cable reinforcement system incorporates impact detection sensors that provide feedback about side impact conditions to the actuation system. When sensors detect impact forces or potential impacts, they trigger the actuators to tension or relax the cables accordingly. This feedback mechanism enables the system to adapt to different impact conditions automatically without requiring complex control algorithms, maintaining ease of manufacture while achieving high adaptability.
Solution Approach 2:
The cable reinforcement system is designed to self-regulate its tension state based on impact detection without requiring complex external control systems. The impact sensors directly trigger the actuators to adjust cable tension, creating a self-service control loop. This self-regulating capability provides high adaptability to different impact conditions while minimizing the complexity of the control system, thereby maintaining ease of manufacture and assembly.
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 cable reinforcement system effectively distributes impact forces across pillars, reducing door intrusion and enhancing occupant safety by maintaining tension during side impacts and releasing it when not necessary, thus improving the structural integrity and safety performance in crash tests.
Implementation Method 1
The cable is moveable to a deployed position by the rotational actuator and is under tension in the deployed position
Implementation Method 2
The rotational actuator may include a pyrotechnic charge
Data Source
AI summary
A vehicle includes a first pillar and a second pillar spaced from the first pillar along a vehicle-longitudinal axis. A rotational actuator is disposed at the first pillar. The rotational actuator is fixed relative to the first pillar. A cable is engaged with the rotational actuator and is elongated along the vehicle-longitudinal axis to the second pillar. The cable is moveable to a deployed position by the rotational actuator and is under tension in the deployed position.