Front Frame Assembly With Deformable Crash Absorption Zones
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Solution Overview
Problem
Motor vehicles with a small front projection, such as electric or rear-engine vehicles, face challenges in efficiently absorbing front crashes due to limited collapsible element length and the mechanical weaknesses of shock towers, which are typically casted and have unpredictable tensile strength.
Innovation Solution
A front frame assembly with a shock tower structure and extruded absorption elements connected to a steering system, featuring controlled deformable regions and openings to manage deformation and tensile strength, ensuring effective crash absorption and motor protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the front projection of the vehicle is reduced to enable compact design, then the vehicle size is reduced, but the length of collapsible elements is limited and crash absorption efficiency deteriorates
Solution Approach 1:
The shock tower is divided into a rigid portion and a deformable portion, allowing different regions to serve different functions. The rigid portion maintains structural integrity while the deformable portion absorbs crash energy through controlled deformation, enabling effective crash absorption in a compact space.
Solution Approach 2:
Different portions of the shock tower are assigned different mechanical properties: the rigid portion has high strength and stiffness, while the deformable portion has controlled lower strength to enable predictable deformation. This local differentiation allows the structure to both protect and absorb energy within limited space.
2Ease of manufacture
If shock towers are manufactured by casting processes, then manufacturing is simplified, but the tensile strength behavior becomes unpredictable and mechanical features are weaker
Solution Approach 1:
The shock tower is designed with specific geometric parameters that control its mechanical behavior. By carefully designing the shape and dimensions of the rigid and deformable portions, the tensile strength and deformation characteristics are made predictable, overcoming the limitations of casting processes.
3Reliability
If collapsible elements are made longer to improve crash absorption, then crash energy absorption is enhanced, but the front projection of the vehicle must be increased
Solution Approach 1:
Instead of extending the collapsible elements only in the longitudinal direction, the shock tower utilizes the vertical and transverse dimensions by creating a multi-region structure with rigid and deformable portions. This allows crash energy absorption to occur in multiple dimensions within a compact footprint.
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 assembly effectively absorbs front crashes, manages deformation, and protects the motor by limiting deceleration and translation, while allowing for a compact vehicle design.
Implementation Method 1
said collapsible elements deform, absorbing the energy of the crash
Implementation Method 2
extruded aluminium elements are deformable along the forward moving direction of the vehicle relative to compression stresses
Data Source
AI summary
Front frame assembly for a motor vehicle comprising a suspension attachment structure, which can be fixed to a body cell of the motor vehicle defining a passenger compartment of said motor vehicle; and an absorption element adapted to absorb the energy associated with a front crash of the motor vehicle; the absorption element being distinct from the structure, being fixed to the latter and extending along a first direction. The structure comprises a first opening adapted to be passed through by a component of a steering system of the motor vehicle, a second opening having an elongated shape along a second direction transversal to the first direction; and at least one third opening opposite the second opening with respect to the first opening.