Powertrain Catcher Bracket for Hybrid Vehicle Crash Safety
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Solution Overview
Problem
Hybrid electric vehicles face increased kinetic energy transfer to the passenger compartment due to the added mass and reduced space for energy absorption, leading to higher intrusion and deceleration pulse in collisions, which compromises safety in crash tests.
Innovation Solution
A powertrain catcher bracket decouples the engine/transmission sub-frame from the vehicle body structure during collisions, using a tubular body with fasteners to detach the sub-frame from the body structure, allowing the powertrain to slide below the passenger compartment and reduce intrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a dual powertrain (electric motor/combustion engine) is added to increase vehicle functionality, then the powertrain mass and kinetic energy increase, but the space available for absorbing energy in a collision decreases
Solution Approach 1:
The vehicle structure is segmented into a powertrain subframe and the main body structure, connected through a catcher bracket. This segmentation allows the powertrain to be isolated from the passenger compartment during collisions, enabling independent energy absorption pathways and resolving the contradiction between having a heavy dual powertrain and maintaining safe passenger space.
2Weight of moving object
If the powertrain mass increases due to dual powertrain components, then the kinetic energy exerted by the powertrain on the vehicle body increases, but the passenger compartment safety deteriorates
Solution Approach 1:
The catcher bracket acts as an intermediary element between the powertrain subframe and the vehicle body. During normal operation, it maintains the subframe in a spaced relationship from the body. During a collision, it serves as the primary load path, absorbing and redirecting the kinetic energy from the heavy powertrain away from the passenger compartment, thus protecting occupants despite the increased powertrain mass.
3Volume of stationary object
If the space for energy absorption is reduced to accommodate dual powertrain components, then the vehicle layout efficiency improves, but the deceleration pulse severity increases
Solution Approach 1:
The catcher bracket is designed with dynamic characteristics that allow it to deform and absorb energy during collisions. The bracket's structural design enables it to progressively collapse and absorb the deceleration pulse from the powertrain, transforming the rigid connection into a dynamic energy-absorbing mechanism that reduces peak forces transmitted to the passenger compartment.
Data Source
AI summary
A catcher bracket disposed between a powertrain and a sub-frame of a vehicle. The catcher bracket defines a load path in a collision that is sufficient to displace the powertrain that directs the force of the impact through the catcher bracket to a sub-frame of the vehicle. The sub-frame is connected to the body structure of the vehicle by fasteners that fracture to decouple the powertrain and sub-frame from the body structure of the vehicle to reduce the collision pulse.