Tubular Back Beam with Segmented Brackets for Offset Crash Rigidity
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Solution Overview
Problem
Conventional tubular back beams for vehicles have low connecting rigidity, leading to separation during crashes, and lack effective structures for offset crashes, resulting in increased vehicle damage and occupant injury.
Innovation Solution
The tubular back beam design includes upper and lower beams with a tubular structure, multiple connecting lugs, a center bracket, and side brackets to enhance rigidity, with elliptical or rectangular cross-sections for improved crashworthiness, and optimized spacing and lug intervals to manage crash energy effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If only one connecting bracket is used to connect upper and lower beams, then the structure is simple and cost-effective, but the connecting rigidity is low causing beam separation during crashes
Solution Approach 1:
The single connecting bracket is segmented into multiple connecting brackets (first and second connecting brackets) positioned at different locations along the upper and lower beams. This segmentation increases connecting rigidity by distributing connection points, preventing beam separation during crashes while maintaining structural simplicity through standardized bracket designs.
2Reliability
If upper and lower beams are connected with multiple brackets at different positions, then crash energy distribution is improved, but manufacturing complexity increases
Solution Approach 1:
The connecting brackets are designed with universal characteristics, where similar bracket designs are reused at different positions along the beams. This multi-functionality approach allows the same basic bracket structure to serve multiple connection purposes, improving crash energy distribution while minimizing manufacturing complexity through component standardization.
Data Source
AI summary
A tubular back beam for a vehicle is provided to effectively cope with crashes, including a head-on crash, an offset crash, etc., thus promoting excellent crashworthiness, and thereby maximally reducing damage to a vehicle body, in addition to maximally mitigating injuries to a pedestrian and a passenger.