Commercial Vehicle Front Structure Diagonal Side Member Bending
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Solution Overview
Problem
Existing front-end structures for commercial vehicles face challenges in reliably absorbing crash forces and towing forces while accommodating a large-area cooler module, requiring a design that balances structural integrity and production efficiency.
Innovation Solution
The side members are designed to bend diagonally downwards, with a cross member connected to their lower extensions, creating space for a large cooler module and ensuring effective force transmission to stiff longitudinal frame members. This configuration includes a support structure that protrudes obliquely to support the driver's cab and incorporates spring elements for vibration resistance, allowing for a robust and shock-resistant setup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the cross member is positioned higher to maintain ground clearance, then the ground clearance is adequate, but space for the cooler module is insufficient
Solution Approach 1:
The cross member is extended downward in the vertical dimension to create additional space for the cooler module. The extension sections bend diagonally downwards from the side members, positioning the cross member lower without compromising the overall ground clearance of the vehicle, thus resolving the spatial conflict between cooler accommodation and ground clearance requirements
2Area of stationary object
If the cross member is lowered to create space for the cooler module, then space for cooler module is sufficient, but ground clearance is reduced
Solution Approach 1:
The side members are segmented into different sections with varying orientations. The extension sections bend diagonally downwards at specific locations to connect the cross member, allowing the cross member to be positioned lower while the upper portions of the side members maintain the overall structural height for ground clearance. This segmentation enables differential positioning of structural components
3Strength
If the side members are made stiffer to improve crash force absorption, then crash force absorption is improved, but production complexity increases
Solution Approach 1:
The side members incorporate diagonal bending sections instead of straight rigid members. These bent sections are formed from profiled sheet metal through bending processes, which can be manufactured using standard press brake equipment. The curved geometry provides structural strength for crash force absorption while being producible through conventional sheet metal forming techniques, avoiding the need for complex forged or cast 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
The solution provides a robust, efficient, and vibration-resistant front-end structure that effectively supports crash and towing forces, accommodates a large cooler module, and ensures easy assembly and manufacturing, while maintaining adequate ground clearance and decoupling from road excitations.
Implementation Method 1
lateral supports running approximately vertically upwards in the direction of the vertical axis of the vehicle can be attached to the cross member and support the driver's cab in the front area via spring elements connected in between, in particular in the vertical direction
Data Source
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AI summary
The structure has a cross beam (11) connected with frame longitudinal beams (3) that are connected with extension sections (7) by connecting elements. The longitudinal beams are diagonally and downwardly bent in a vehicle longitudinal direction before an extended vehicle center plane of a front wheel (4) in relation to the vehicle longitudinal direction and a vehicle high axis direction. The cross beam is connected to the sections and a lower region in the vehicle high axis direction, and a cooler (15) is positioned in the vehicle high axis direction above the cross beam.