Modular Bumper Crossmember Layout for MPDB Crash Energy Distribution
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Solution Overview
Problem
Existing bumper crossmembers do not adequately meet the requirements for improved crash performance in compatibility crash tests, such as the MPDB crash test, particularly in terms of energy absorption and distribution across a larger vertical and horizontal area.
Innovation Solution
A modular bumper crossmember design featuring a second lower crossmember spaced apart from the upper crossmember, connected by at least two connector parts, with crash boxes on both members to create multiple load paths for energy absorption, and an intended bending point in the upper crossmember to enhance deformation behavior during impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single bumper crossmember is used, then the structure is simple, but the crash performance is insufficient for compatibility crash tests
Solution Approach 1:
The bumper crossmember is divided into an upper crossmember and a lower crossmember that are spatially separated and connected by connector parts. This segmentation creates multiple load paths for energy absorption during crashes, improving crash performance while maintaining manageable structural complexity through modular design
Solution Approach 2:
The invention transitions from a single-plane crossmember structure to a multi-dimensional arrangement by positioning the upper and lower crossmembers at different vertical levels and connecting them through connector parts. This dimensional expansion creates additional load paths and energy absorption zones, enhancing crash performance without excessive complexity
2Area of stationary object
If the crossmember height is increased to improve collision compatibility, then energy absorption area is improved, but the structural complexity increases
Solution Approach 1:
Instead of using one tall crossmember, the structure is segmented into upper and lower crossmembers of moderate height, connected by connector parts. This segmentation achieves the required vertical energy absorption area while keeping individual component heights manageable and structural complexity controlled through modular architecture
Solution Approach 2:
The energy absorption area is expanded by utilizing the vertical dimension through multiple levels (upper and lower crossmembers) rather than relying solely on increasing the height of a single component. This multi-level arrangement achieves the required energy absorption area while maintaining reasonable structural complexity
3Reliability
If multiple load paths are created for better collision compatibility, then crash performance is improved, but the device complexity increases
Solution Approach 1:
The structure is segmented into upper and lower crossmembers with separate crash boxes, creating distinct load paths for energy absorption. This segmentation provides multiple load paths for improved collision compatibility while maintaining manageable complexity through clear functional separation and modular design
Solution Approach 2:
Multiple load paths are created by arranging upper and lower crossmembers at different vertical levels, utilizing the vertical dimension to establish independent energy absorption pathways. This multi-level load path configuration improves collision compatibility while keeping the complexity manageable through spatial separation
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 design significantly improves crash performance by distributing and dissipating impact energy across a larger area, meeting the requirements of compatibility crash tests and enhancing safety by directing energy away from critical components like battery modules.
Implementation Method 1
the lower crossmember is connected to the lower hollow chamber section of the upper crossmember by at least two connector parts
Implementation Method 2
These longitudinal beam components can be so-called crash boxes, which, if a specific impact energy is exceeded, absorb this energy by plastic deformation
Implementation Method 3
The design significantly improves crash performance by distributing and dissipating impact energy across a larger area
Data Source
AI summary
A bumper crossmember for a vehicle having a first crossmember provided by an outer shell facing away from the vehicle and an inner shell facing toward the vehicle, which two shells are connected to one another along their circumference. This crossmember has at least one passage oriented in the direction of its longitudinal extension and extending over its middle with respect to its longitudinal extension (y direction), and by which the crossmember is divided into an upper hollow chamber section and a lower hollow chamber section. Crash boxes arranged at distance from one another are connected to the lower hollow chamber section on its side facing the vehicle. The bumper crossmember has a second lower crossmember spaced apart in the z direction from the lower hollow chamber section and connected by at least two connector parts to the lower hollow chamber section of the first crossmember. Crash boxes arranged at a distance to one another are connected on the side of the second crossmember facing the vehicle.