Vehicle Underrun Protector Beam End Structure
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Solution Overview
Problem
Existing underrun protectors fail to achieve sufficient load resistance performance, leading to inadequate protection during collisions, as they struggle to absorb collision energy and prevent passenger vehicles from becoming wedged under larger vehicles.
Innovation Solution
The proposed end structure of a vehicle incorporates a beam extending in the vehicle width direction, connected to a vehicle body frame via a connecting structure with specific geometrical features such as flange parts, reinforcing members, and a bent beam attachment surface, which enhances load resistance by distributing and managing collision forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a beam is fastened to a vehicle body frame with a bracket or stay, then the underrun protector can be installed, but the load resistance performance is insufficient
Solution Approach 1:
The connection structure is segmented into multiple functional components: a connecting structure with protrusions that engage with the beam, flange parts that extend outward, and reinforcing members that bridge gaps. This segmentation allows each component to perform its specific function optimally while collectively achieving high load resistance performance.
Solution Approach 2:
The protrusions are pre-formed on the connecting structure to engage with the beam before collision occurs. The flange parts are pre-positioned to extend outward and prepare for receiving loads. This preliminary configuration ensures that when collision occurs, the structure is already optimized for load resistance without requiring complex assembly during the collision event.
2Strength
If reinforcing members are added to bridge frame attachment part and beam attachment surface, then load resistance performance improves, but device complexity increases
Solution Approach 1:
The reinforcing members are merged with the connecting structure as an integrated component rather than separate attachments. The flange parts are combined with the beam attachment surface to form a unified load-bearing element. This merging reduces the total number of discrete components while maintaining the reinforcing function.
Solution Approach 2:
The connecting structure serves multiple functions simultaneously: it connects the beam to the vehicle body frame, provides reinforcement through integrated members, distributes loads across multiple attachment points, and prevents deformation. This multi-functionality eliminates the need for separate components for each function, reducing overall device complexity.
3Strength
If the beam is fixed with multiple bonding points (protrusion to top and bottom surfaces, beam attachment member to flange parts), then load resistance performance increases, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into distinct stages: first forming the protrusions on the connecting structure, then attaching the beam attachment member to the flange parts, and finally bonding the protrusions to the beam surfaces. This segmentation allows each manufacturing step to be optimized independently and performed by specialized processes.
Solution Approach 2:
The protrusions are pre-formed on the connecting structure before final assembly with the beam. The beam attachment member is pre-attached to the flange parts. These preliminary actions simplify the final assembly process by reducing the number of steps required during manufacturing and enabling parallel processing of different components.
Data Source
AI summary
[Object] To improve load resistance performance in response to collision.[Solution] An end structure of a vehicle according to the present invention includes: a beam 2 that extends in a vehicle width direction; and a connecting structure 3 that connects the beam 2 to a vehicle body frame. In a cross-sectional view perpendicular to the vehicle width direction, the beam 2 includes a first top surface part 2a and a first bottom surface part 2b which face each other, a first side surface part 2c that connects one ends of the first top surface part 2a and the first bottom surface part 2b, and first flange parts 2d that are formed to protrude vertically outwardly at the other ends of the first top surface part 2a and the first bottom surface part 2b. The beam 2 is fixed to the connecting structure 3 by at least one of bonding of a protrusion 6 that is provided in the connecting structure 3 and is arranged to protrude inside the beam 2 to the first top surface part 2a and the first bottom surface part 2b and bonding of a beam attachment member provided in the connecting structure 3 to the first flange parts 2d.