Offset Frontal Load Management via Frame Rail Powertrain Engagement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle body structures are inadequate in managing lateral loads applied to the forward corner, as they fail to effectively distribute and absorb such loads, leading to insufficient lateral stiffness and acceleration during offset frontal impacts.
Innovation Solution
The vehicle body structure incorporates flared and splayed frame rails with variable cross-sectional areas and reinforcing members that deform laterally to engage the powertrain system, generating a lateral force and enhancing lateral acceleration by distributing the load across a rigid component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the frame rail is designed with conventional uniform cross section, then manufacturing is simple, but lateral stiffness and load management capability are insufficient during offset frontal impacts
Solution Approach 1:
The frame rail employs a non-uniform cross-sectional geometry where the height varies along its length. Specifically, the cross-sectional height is greater at locations farther from the bulkhead and smaller near the bulkhead. This local variation in geometric properties optimizes the lateral stiffness distribution, providing enhanced load management capability at the forward corners while maintaining manufacturing feasibility through controlled geometric progression.
Solution Approach 2:
The frame rail design incorporates a dynamic geometric progression where the cross-sectional height changes continuously along the length of the rail. This dynamic variation allows the structure to adapt its stiffness characteristics along its span, with taller sections providing higher lateral stiffness for load management during offset impacts, while shorter sections near the bulkhead reduce unnecessary weight and material usage.
2Loss of energy
If the frame rail deforms laterally to engage the powertrain system, then load absorption and lateral acceleration are enhanced, but structural integrity may be compromised
Solution Approach 1:
The frame rail incorporates energy-absorbing features such as controlled deformation zones and geometric transitions that are designed to deform in a predictable manner during offset frontal impacts. The varying cross-sectional height creates progressive deformation characteristics, allowing the rail to absorb impact energy through controlled plastic deformation while maintaining sufficient structural integrity to protect the powertrain system and cabin.
Solution Approach 2:
The frame rail utilizes changes in geometric parameters, specifically the cross-sectional height varying along the length, to control deformation behavior. The taller sections farther from the bulkhead provide greater energy absorption capacity during impact, while the overall geometric configuration ensures that deformation remains within acceptable limits to maintain structural integrity and protect critical vehicle components.
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
This configuration effectively manages lateral loads by deforming into contact with the powertrain system, enhancing lateral acceleration and load absorption, thereby improving vehicle stability during offset frontal impacts.
Implementation Method 1
The frame rail is operable to deform into contact with the powertrain system in response to a load applied to a forward end of the body structure and laterally offset from the longitudinal centerline, to generate a lateral force in the body structure
Data Source
AI summary
A body structure of a vehicle includes a bulkhead, and a frame rail extending forward from the bulkhead along a longitudinal centerline. A powertrain system is disposed laterally inboard of the frame rail relative to the longitudinal centerline. The frame rail includes a flared section, a splayed section, and a reinforcing member. The flared section curves laterally outboard, away from the longitudinal centerline. The splayed section includes a variable cross sectional area that increases with an increase in distance from the bulkhead. The reinforcing member is operable to increase lateral stiffness in the frame rail, in a direction transverse to the longitudinal centerline. The frame rail is operable to deform into contact with the powertrain system in response to a load applied to a forward end of the body structure and laterally offset from the longitudinal centerline, to generate a lateral force in the body structure.