Front Underrun Protection Assembly Flange Force Transfer
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Solution Overview
Problem
Existing front underrun protection assemblies in heavy goods vehicles are heavy, complex, and do not efficiently transfer collision forces, which affects safety and fuel economy.
Innovation Solution
A front underrun protection assembly with a cross beam connected to parallel frame beams via brackets, featuring support elements with a flange that projects rearwardly to engage with the bracket during a collision, efficiently transferring forces without additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional front underrun protection assemblies are used, then safety requirements are met, but the weight of the assembly increases
Solution Approach 1:
The support elements have different structural characteristics in different regions: the first support element has an L-shaped cross-section providing structural strength, while the second support element has a channel cross-section with a flange for force transfer. This local differentiation allows optimized weight distribution while maintaining safety performance.
Solution Approach 2:
The front underrun protection assembly combines different structural configurations of support elements (L-shaped and channel cross-sections) with flanges and webbing to create a composite structural system that achieves high strength-to-weight ratio, reducing overall assembly weight while meeting safety requirements.
2Force
If additional components are added to improve force transfer, then collision force transfer efficiency improves, but device complexity increases
Solution Approach 1:
The flange is integrated directly into the second support element's channel cross-section, merging the force transfer function with the structural support function. This eliminates the need for separate force transfer components while achieving efficient collision force transfer from the outer support element through the flange to the bracket.
Solution Approach 2:
The second support element with channel cross-section serves multiple functions: providing structural support, enabling force transfer through its flange, and connecting both the outer support element and the bracket. This multi-functionality reduces the number of separate components needed in the assembly.
3Stability of the object's composition
If support elements are connected at different heights, then structural stability improves, but manufacturing complexity increases
Solution Approach 1:
The flange of the second support element is positioned at the same height level as the bracket connection point, creating an equipotential connection that simplifies manufacturing and assembly. This aligned positioning allows for straightforward welding or bolting operations without complex angular adjustments, while the flange's extended geometry still provides the necessary structural stability for force transfer.
Data Source
Figure 1~2
Figure 3
AI summary
A vehicle having a front underrun protection assembly (1) provided at the front of the vehicle. The front underrun protection assembly comprises two couples of support elements (7, 8; 9, 10) for connection of the cross beam (2) to the brackets (5, 6). One couple of support elements is arranged for connection of the cross beam to a respective bracket. Each couple of support elements includes a horizontally extending outer support element (8; 10) connected to an end portion of the cross beam and extending obliquely from the cross beam and an inner support element connected to the cross beam and horizontally extending parallel to the longitudinal direction of the vehicle. The outer support element is connected to the flange and a portion of the outward side of the inner support element adjacent the flange (7D). The flange extends along the outward part of the respective bracket and a space (S) is present between the flange of the inner support element and the outward part of the respective bracket.