Underride Crossmember Offset for Cooler Module Protection
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Solution Overview
Problem
Existing front-end structures for commercial vehicles are vulnerable to damage in frontal crashes, as the radiator module is exposed and air inflow areas are obstructed by crossmembers, limiting deformation paths and cooler module arrangements.
Innovation Solution
The underride protection crossmember is offset rearward of the bumper crossmember, allowing the cooler module to be positioned behind deformation elements, creating a deformation path and additional installation space, while being connected to the longitudinal frame members via vertical struts and lower longitudinal members for enhanced rigidity and airflow access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the cooler module is positioned close behind the crossmembers, then the installation space is reduced, but the cooler module becomes more susceptible to damage in frontal crashes
Solution Approach 1:
The patent offsets the underride protection crossmember rearward relative to the bumper crossmember by dimension 'a' in the longitudinal direction, creating a staggered arrangement. This dimensional offset allows the cooler module to be positioned in a protected zone behind the bumper crossmember while maintaining adequate installation space, effectively using longitudinal positioning to resolve the contradiction between space and protection.
2Area of stationary object
If the crossmembers are drawn up to the lateral vehicle outer contour, then the structural coverage is maximized, but the air inflow openings for cooler modules are obstructed
Solution Approach 1:
The patent divides the crossmember system into two separate components: the bumper crossmember extending to the lateral vehicle outer contour for structural coverage, and the underride protection crossmember offset rearward to avoid obstructing air inflow openings. This segmentation allows each component to fulfill its specific function without interfering with the other, resolving the contradiction between coverage area and airflow access.
3Adaptability or versatility
If the bumper crossmember is connected to frame side members via deformation elements, then the deformation path is created for crash energy absorption, but the structural rigidity is reduced
Solution Approach 1:
The patent applies different structural qualities to different parts of the crossmember system: the bumper crossmember incorporates deformation elements with lower rigidity to create deformation paths for energy absorption, while the underride protection crossmember is constructed with higher rigidity to provide stable support for the cooler module. This local differentiation of structural properties allows the system to simultaneously achieve crash energy management and structural stability.
Data Source
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AI summary
The front-end structure has lateral frame longitudinal carriers (2), a bumper cross beam (3) and a cross beam, which is arranged below the bumper cross beam and serves as an underride guard. The cross beam carries a radiator module (5), which is arranged behind the bumper cross beam and between the lateral frame longitudinal carriers. The underride guard-cross beam (4) is displaced backwards to the bumper cross beam about a longitudinal offset to the vehicle outer contour to carry the radiator module.