Underride Guard with Merged Support Bracket
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Solution Overview
Problem
Existing underrun protection systems for commercial vehicles are complex and costly due to numerous components, and there is a need for weight optimization while maintaining functional reliability.
Innovation Solution
The design simplifies the underrun protection system by using fewer components, featuring a single support bracket with a stop for force transfer, a U-shaped or L-shaped reinforcing element, and a locking device for pivoting, reducing material usage and weight through shaped sheet metal parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two identical support brackets are used as in prior art, then the underrun protection can absorb impact forces reliably, but the structural design becomes complex and expensive with increased weight
Solution Approach 1:
The patent combines two separate support brackets into a single support bracket with two stops. The single support bracket is articulated to the connection element and carries two stops (3a, 3b) that respectively support the two supporting beams (4a, 4b) in their lowered functional positions. This merging reduces the number of components while maintaining the ability to absorb impact forces from both sides simultaneously.
Solution Approach 2:
The single support bracket serves multiple functions: it supports both supporting beams (4a, 4b) in their lowered positions via stops 3a and 3b, provides force transfer paths for both sides during impact, and maintains the structural integrity of the underrun protection system. This multi-functionality eliminates the need for separate support brackets while preserving reliability.
2Reliability
If multiple individual parts are used in the underrun protection system, then functional reliability is maintained, but production becomes costly and weight optimization is compromised
Solution Approach 1:
The patent merges multiple individual parts into fewer components. Specifically, two support brackets are combined into one support bracket with two stops, reducing the total number of parts and consequently the overall weight of the underrun protection system while maintaining functional reliability through the preserved force transfer mechanism.
Solution Approach 2:
The support bracket and supporting beams are designed as shaped sheet metal parts, which optimize material usage and reduce weight compared to traditional multi-component assemblies. The integrated design allows for optimized material distribution and reduced redundancy.
3Device complexity
If a single support bracket with stop is used, then the number of components is reduced and weight is optimized, but the force transfer mechanism must be redesigned
Solution Approach 1:
The support bracket is segmented to include two distinct stops (3a, 3b) that independently support the two supporting beams (4a, 4b). This segmentation within a single component allows each stop to handle force transfer for its corresponding beam separately, simplifying the overall design while maintaining proper force distribution and transfer mechanisms.
Data Source
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AI summary
An underride guard for a commercial vehicle, comprising at least one vehicle-side fixed connection element (1), a support beam (4) pivotably connected thereto, to which a crash bar (5) is attached at its end, and a support bracket (2) which is hinged on the connection element (1) on the one hand and, on the other hand, is guided on the support beam (4) and is movable relative to it in the pivoting direction, wherein the support bracket (2) has a stop (3) against which the support beam (4) rests in the pivoted functional position.