Vehicle Front End Module Box-Type Mounting Stiffness
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Solution Overview
Problem
The existing front end module connection structures between the front side member and the front end module lower member in vehicles suffer from reduced stiffness, leading to booming and compromised low-speed crash performance due to sectional disconnection, limiting the reinforcement of the connection part and assembly workability.
Innovation Solution
The implementation of box-type mounting parts on both the front end module lower member and the front side member, allowing for bolt coupling or welding to connect the sections, thereby enhancing the stiffness and structural integrity of the connection area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the front end module lower member is connected to the front side member through a conventional connection structure, then the assembly can be easily manufactured, but the stiffness of the connection part is reduced leading to booming and reduced vehicle body stiffness
Solution Approach 1:
The patent merges the connection structure by integrating a reinforcement rib directly into the lower member of the front end module, forming a unified structure that combines the lower member and reinforcement rib as a single integrated component. This merging approach increases the stiffness of the connection part between the lower member and front side member while avoiding the need for separate reinforcement components, thus resolving the contradiction between strength improvement and device complexity.
2Ease of manufacture
If the connection structure is simplified to improve assembly workability, then the manufacturing process is easier, but the low-speed crash performance is compromised due to reduced stiffness
Solution Approach 1:
The patent applies preliminary action by pre-forming the reinforcement rib as an integral part of the lower member during the molding process, rather than adding it as a separate component during assembly. This preliminary integration ensures that the reinforcement structure is already in place to enhance stiffness and crash performance before the assembly operation, maintaining both ease of manufacture and reliability.
3Strength
If separate connection brackets are used to reinforce the connection part, then the stiffness can be increased, but the number of components increases and assembly complexity is reduced
Solution Approach 1:
The patent merges the function of separate connection brackets into the integrated lower member structure itself. The reinforcement rib is formed as a single integrated component with the lower member, eliminating the need for separate brackets while achieving the same stiffness enhancement. This reduces the total number of components and simplifies the assembly process.
Data Source
AI summary
A front end module for a vehicle includes a first box-type mounting part and a second box-type mounting part. The first box-type mounting part is disposed on a connection portion of a front end module lower member with a front side member. The second box-type mounting part is disposed on a front end portion of the front side member. The first and second box-type mounting parts are coupled to each other by bolt coupling or welding such that sections thereof are connected to each other upon assembling of the front end module and the front side member.