Vehicle Subframe Homogeneous Plate Design for Collision Energy Management
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Solution Overview
Problem
Existing vehicle subframes face challenges in achieving high strength and rigidity while maintaining required collision performance, particularly when using press-formed products as main constituents, as they tend to require complex welding processes and may not meet the necessary collision performance standards.
Innovation Solution
A vehicle subframe design featuring a pair of side members and a cross member formed from plate members, with specific mounting and reinforcement configurations that distribute impact forces and absorb energy during collisions, including weakened and reinforcement portions to manage deformation effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If aluminum alloy press-formed products and cast products are used in combination for subframe members, then the subframe can achieve required strength and rigidity, but the configuration becomes more complex and requires many types of welding processes
Solution Approach 1:
The patent applies homogeneity by uniformly using press-formed steel plate members for all main subframe components (side members, cross members, and mounting members), eliminating the need to combine different manufacturing methods. This simplifies the configuration and reduces welding process complexity while maintaining required strength through optimized plate member designs including reinforced portions and integrated mounting member structures.
2Strength
If aluminum alloy press-formed products and cast products are used in combination for subframe members, then the subframe can achieve required strength and rigidity, but the design work for collision performance becomes complicated
Solution Approach 1:
The patent simplifies collision performance design by using uniform press-formed steel plate members throughout the subframe structure. This homogeneity allows for more straightforward design and analysis of collision behavior, as all components respond predictably to impact forces. The integrated mounting members and reinforced portions are designed as continuous plate structures, eliminating the design complications that would arise from joining dissimilar materials and manufacturing processes.
3Strength
If the subframe is designed with high strength and rigidity, then collision performance can be improved, but the subframe may not deform in the desired deformation mode for absorbing kinetic energy
Solution Approach 1:
The patent applies local quality by creating reinforced portions with increased plate thickness or structural reinforcement at specific locations (such as mounting member attachment areas and cross-member junctions) while maintaining standard thickness in other areas. This localized strengthening provides high strength and rigidity where needed for collision energy absorption and controlled deformation, while allowing other portions to deform as intended during collision events.
Solution Approach 2:
The integrated mounting members are designed with reinforced portions that preemptively strengthen critical load paths before collision occurs. The mounting members extend from the side members and are formed as integral structures with the cross members, creating predetermined strong connection points that guide the deformation mode during collision and ensure reliable kinetic energy absorption.
4Productivity
If press-formed products are used as main constituent members of the subframe, then manufacturing productivity can be improved, but the subframe may not achieve the necessary strength and rigidity and collision performance
Solution Approach 1:
The patent maintains high productivity by using press-formed steel plate members for all subframe components, but overcomes strength and rigidity limitations through parameter changes in the plate member designs. This includes increasing plate thickness in critical areas, optimizing structural geometry with reinforced portions, and designing integrated mounting members that extend and connect to multiple components. These parameter adjustments enable press-formed members to achieve the required mechanical performance while maintaining manufacturing efficiency.
Data Source
AI summary
In a vehicle subframe 1, a pair of side members 110 and 130 includes upper side members 111 and 131 and lower side members 117 and 137, respectively, the lower side members 117 and 137 extending opposed on a downward side to the upper side members 111 and 131 while being elongated to a rearward side, and a pair of mounting members 60 and 80 is joined respectively to the lower side members 117 and 137 of the pair of side members 110 and 130.