Front End Module Actuating Rod for Small Overlap Crash Protection
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Solution Overview
Problem
The existing technologies fail to adequately address the risk of damage to a front wheel during a small overlap crash in motor vehicles, where only part of the bumper is loaded upon impact, leading to potential deformation and damage.
Innovation Solution
A front end module with a cross member connected to the vehicle frame, featuring a pivotable actuating rod that rotates the front wheel radially within the wheel rim ring, avoiding unnecessary deformation and tire contact, and utilizing a crash element for energy absorption and load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the cross member is deformed plastically into the wheelhouse during a small overlap crash, then the impact energy is absorbed, but the front wheel is damaged
Solution Approach 1:
The actuating rod is pre-positioned to engage with the rim before crash occurs. When the cross member deforms during small overlap crash, the actuating rod is automatically pivoted outward to rotate the front wheel away from the deformation zone before the wheel can be damaged by the intruding cross member end piece.
Solution Approach 2:
The harmful plastic deformation of the cross member during small overlap crash is converted into a beneficial action by using the deformation-induced movement to pivot the actuating rod, which in turn rotates the front wheel away from the danger zone. The crash energy that would otherwise damage the wheel is instead used to activate the protective mechanism.
2Ease of operation
If the actuating rod contacts the tire to rotate the front wheel, then the wheel can be rotated out of the deformation zone, but the tire is damaged
Solution Approach 1:
The actuating rod is designed to contact only the rim (specifically the wheel rim ring) and not the tire. The gripping surface is localized to the rim area, ensuring that the rotational force is applied precisely where needed without affecting the tire structure.
3Speed
If the actuating rod is coupled rigidly to the cross member, then the wheel rotation is immediate, but unnecessary wheel rotation occurs in less hard crashes
Solution Approach 1:
The coupling between the actuating rod and cross member is designed with travel reinforcement that allows partial movement. The actuating rod can pivot only when the cross member deformation exceeds a certain threshold, enabling wheel rotation only in severe crashes where it is truly needed, while avoiding unnecessary rotation in minor impacts.
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 solution effectively reduces the risk of front wheel damage by rotating the wheel out of the deformation path during a small overlap crash, ensuring satisfactory crash behavior and minimizing tire damage through controlled force application and energy absorption.
Implementation Method 1
The actuating rod is pivotable relative to the front wheel by means of a relative movement of at least part of the cross member. The relative movement of at least part of the cross member takes place in the direction of travel of the motor vehicle.
Implementation Method 2
The cross member also is deformed plastically in this case, for example, by a laterally protruding end piece of the cross member being bent into the motor vehicle by means of the impact of the motor vehicle against the obstacle in the small overlap crash.
Data Source
AI summary
A front end module (10) has a cross member (12) that connects to longitudinal members (14) of a motor vehicle frame for carrying away loads from a bumper. An actuating rod (18) can pivot relative to the front wheel (22) due to relative movement of a part of the cross member (12) in the direction of travel of the motor vehicle during a small overlap crash. The actuating rod (18) in the pivoted-out state for rotating the front wheel (24) radially within a wheel rim ring (28) of the rim (22) can be gripped at the rim (22). Damage to the front wheel (24) by plastic deformation of the front end module (10) and by the actuating rod (18) can be avoided to permit satisfactory crash behavior of a motor vehicle.