Four Rail Front Crush Structure for Mid-Engine Load Distribution
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Solution Overview
Problem
Mid-engine vehicles face challenges in efficiently transferring front external loads into structural members due to the empty space in front of the passenger compartment, which complicates force transmission and reduces structural rigidity compared to front-engine vehicles.
Innovation Solution
A structural system comprising an elongated single member torsional box and eight diagonal support members, along with four rails and vehicle body side members, is designed to efficiently transmit frontal forces through the vehicle body, utilizing different materials for varying strength requirements and optimized angles for effective force distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a mid-engine configuration is used to prioritize packaging for occupants, powertrain, and cooling systems, then cargo space and occupant packaging are improved, but structural rigidity and force transmission capability deteriorate due to the empty space in front of the passenger compartment
Solution Approach 1:
The front crush structure is segmented into four separate rails instead of a single monolithic structure. These rails are positioned at the vehicle corners and connected through diagonal support members, creating a distributed load path that effectively transmits frontal forces to the passenger compartment without requiring a large mass in the engine bay area.
Solution Approach 2:
The structure transitions from a traditional front-engine mass-based force transmission to a multi-dimensional load path using four rails positioned at vehicle corners connected by diagonal support members. This creates a three-dimensional force distribution network that efficiently transmits loads through the vehicle body structure rather than relying on longitudinal mass.
2Force
If four rails are used in a vehicle-forward position, then frontal force distribution is improved, but the complexity of the structural system increases
Solution Approach 1:
The four rails are closely coupled and connected through diagonal support members to function as an integrated load-bearing system. The rails and diagonal supports work together to distribute frontal forces across the vehicle width and transmit them to the passenger compartment, combining multiple elements into a unified structural solution.
Solution Approach 2:
The structure uses diagonal support members that create three-dimensional load paths between the four rails and the passenger compartment. This diagonal bracing system adds a spatial dimension to force transmission, efficiently distributing loads through the vehicle body structure.
Data Source
AI summary
A system for providing structural transmittal of force through a vehicle body of a mid-engine vehicle is provided. The system includes an elongated single member torsional box spanning a passenger compartment. The system further includes two vehicle body side members spanning an outer lateral edge of the passenger compartment. The system further includes four rails parallel to the longitudinal axis of the vehicle body. The system further includes four inner diagonal support members, each inner diagonal support member being connected at a first end to one of the four rails and on the second end to the elongated single member torsional box and being configured to transmit force from the one of the four rails to the single member torsional box. The system further includes four outer diagonal support members, each outer diagonal support member being configured to transmit force to one of the vehicle body side members.