Secondary Load Beam Counterbalances Sill Drop in Vehicle Frame

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Solution Overview

Problem

Existing vehicle frame modifications, such as adding vertical support members and reinforcement, are insufficient in preventing sill drop during frontal impacts, as they fail to effectively counterbalance the downward movement of vehicle sills, compromising passenger safety.

Innovation Solution

A front end frame assembly that includes a first load beam, a frame rail, and a secondary load beam, where the secondary load beam is configured to counterbalance the energy applied to the sill by transferring it to the frame rail, thereby reducing the downward movement of the sill during a frontal impact. The secondary load beam is attached to the load beam and frame rail in a specific configuration, with a greater length fixed to the frame rail than to the load beam, ensuring efficient energy transfer and absorption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If vertical support members and reinforcement members are added to the vehicle frame, then the stiffness of the sills is increased, but the downward movement of the sills during impact is not sufficiently reduced

Engineering Contradiction:

Improvesill stiffnessVSAvoidsill drop prevention

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The energy transfer path is segmented into multiple components: the first load beam receives energy from the impact, the second load beam transfers energy to the frame rail, and the frame rail itself absorbs energy through its multi-section design. This segmentation creates multiple barriers to sill drop, where each component performs a specific function in the energy management chain, preventing any single point of failure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The solution moves beyond simple vertical reinforcement by introducing a multi-dimensional energy transfer system. The frame rail's lead, intermediate, and trail sections create a three-dimensional energy distribution network that redirects impact forces through multiple paths, not just vertical support, thereby more effectively preventing sill drop.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Use of energy by moving object

If the second load beam is configured with greater length fixed to the frame rail than to the load beam, then energy transfer efficiency is improved, but the device complexity increases

Engineering Contradiction:

Improveenergy transfer efficiencyVSAvoidframe assembly complexity

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The optimal length ratio of the second load beam is determined by analyzing energy transfer parameters. By setting the beam fixed to the frame rail longer than the portion fixed to the load beam, the system optimizes the leverage and energy distribution parameters, maximizing the counterbalancing effect on sill drop while maintaining manufacturability.

Inventive Principle:

Principle #35Parameter changes

3Loss of energy

If the frame rail includes multiple sections (lead, intermediate, trail) with varying thicknesses, then energy absorption capacity is increased, but manufacturing complexity increases

Engineering Contradiction:

Improveenergy absorption capacityVSAvoidframe rail manufacturing

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

Different sections of the frame rail are designed with locally optimized properties: the lead section at the front, the intermediate section with greater thickness for maximum energy absorption, and the trail section connecting to the sill. Each section's thickness and geometry are tailored to its specific functional requirements in the energy absorption sequence, allowing efficient energy dissipation while maintaining manufacturing feasibility through modular construction.

Inventive Principle:

Principle #3Local quality

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 secondary load beam effectively reduces the sill drop distance during a frontal impact by counterbalancing the downward force, allowing the frame components to absorb more energy and prevent deformation of the hinge pillar, enhancing occupant protection by limiting frame intrusion into the cabin.

Implementation Method 1

the second load beam being configured to transfer the energy received form the first load beam to the frame rail such that the transfer of energy to the sill that can move the sill in the downward direction is counterbalanced by the energy transferred by the second load beam to the frame rail

Methodology Applied

Scientific EffectEnergy transfer:

Implementation Method 2

allowing the frame components to absorb more energy and prevent deformation of the hinge pillar

Methodology Applied

Scientific EffectEnergy absorption:

Data Source

PatentUS11613309B2Vehicle frame assembly including secondary load beam to reduce sill drop

Publication Date: 2023.03.28 FCA US LLC

AI summary

A frame assembly for a motor vehicle that may include a first load beam, a second load beam, and a frame rail that are configured for receipt and transfer of energy to a sill that can move the sill in a downward direction. A counterbalancing load beam that includes a first fixed end is attached to the first load beam and a second fixed end is attached to the frame rail. The counterbalancing load beam is configured for receipt of at least a portion of the energy applied to the first load beam, and the counterbalancing load beam is configured to transfer the energy received from the first load beam to the frame rail such that the transfer of energy to the sill that can move the sill in the downward direction is counterbalanced by the energy transferred by the counterbalancing load beam to the frame rail.