Underrun Protector Stay Structure Torsional Resistance
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Solution Overview
Problem
Existing underrun protector structures fail to adequately improve load bearing performance due to issues with torsional deformation and weight, particularly when loads are applied outside the stay attachment position of the beam in a vehicle width direction.
Innovation Solution
A supporting structure for an underrun protector featuring a stay body with a vertically oriented web face and outwardly extending wall face parts that abut against a stay reinforcing body at the height of a gusset, forming a closed section to enhance resistance against torsional moments and reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional stay structure is used to connect the beam and frame, then the structure is simple and easy to manufacture, but the load bearing performance is insufficient and torsional deformation occurs when loads are applied outside the stay attachment position
Solution Approach 1:
The stay structure is divided into multiple components: a stay body, a stay reinforcing body with closed-section configuration, and gussets. This segmentation allows each component to perform specific functions - the stay body provides basic support, the reinforcing body resists torsional moments through its closed-section geometry, and the gussets distribute loads effectively, collectively improving load bearing performance while maintaining manufacturability
Solution Approach 2:
The stay structure employs a composite configuration combining the stay body and stay reinforcing body into an integrated assembly. The reinforcing body acts as a structural composite that enhances the torsional stiffness and load bearing capacity of the overall stay system without requiring exotic materials, thus improving strength while keeping the structure manufacturable
2Strength
If the stay body is made solid without openings to increase strength, then resistance to torsional deformation improves, but the weight of the underrun protector increases
Solution Approach 1:
The stay reinforcing body is designed with a closed-section configuration that provides maximum torsional resistance only where needed - in the regions subjected to torsional moments. This localized reinforcement approach allows the structure to achieve high torsional stiffness without solidifying the entire stay body, thereby minimizing unnecessary weight addition while maintaining strength where required
Solution Approach 2:
The closed-section configuration of the stay reinforcing body utilizes a hollow tubular geometry that provides high torsional stiffness-to-weight ratio. This dimensional approach creates a structure that resists torsional deformation effectively through its geometric configuration rather than through increased material quantity, achieving strength without proportional weight increase
3Strength
If the wall face parts extend further in the vehicle width direction to increase contact area with the stay reinforcing body, then the resistance to torsional moment improves, but the complexity of manufacturing increases
Solution Approach 1:
The wall face parts extend sufficiently in the vehicle width direction to provide adequate contact area with the stay reinforcing body for resisting torsional moments, but not excessively so. This partial extension approach achieves the necessary structural performance while avoiding over-engineering that would complicate manufacturing, striking an optimal balance between strength and ease of manufacture
Data Source
AI summary
This supporting structure for an underrun protector includes a stay body that connects a beam and a frame to each other; a stay reinforcing body that reinforces the stay body from an outside in a vehicle width direction; and a gusset provided between the stay reinforcing body and the beam. A stay body web face of the stay body is provided with an opening part. A pair of wall face parts provided to extend outward in the vehicle width direction from both ends of the opening part in a vehicle forward-rearward direction is provided so as to face each other. Each of the wall face parts is provided at a height corresponding to an installation position of the gusset and abuts against an inner surface of the stay reinforcing body in the vehicle width direction.