Motor Vehicle Beam Structure for Uniform Crash Load Distribution
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Solution Overview
Problem
Existing beam structures in motor vehicles suffer from asymmetric load effects due to lever actions during crashes, leading to increased loads in the engine longitudinal member, potential plasticization, and improper crumpling behavior, which are not adequately addressed by prior designs.
Innovation Solution
A beam structure comprising shock-absorbing elements with crossmembers and structural elements connected by screws, where the crossmember and structural elements form a force input surface orthogonal to the longitudinal direction, reducing asymmetric load effects by distributing forces evenly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a crossmember is used to connect shock-absorbing beam elements, then the beam structure can be assembled and load paths can be defined, but asymmetric load effects and torque about the Y axis occur during crashes leading to increased loads in the engine longitudinal member
Solution Approach 1:
The beam structure is divided into multiple shock-absorbing beam elements connected by crossmembers and structural elements, creating a segmented framework that distributes crash loads across multiple connection points rather than concentrating them at a single crossmember location
Solution Approach 2:
Structural elements act as intermediary components between the crossmembers and the shock-absorbing beam elements, providing additional connection points that mediate the load transfer and reduce asymmetric torque effects on the engine longitudinal member
2Volume of moving object
If the crossmember is positioned at a lower height, then installation space is optimized, but lever effects increase causing asymmetric load effects and potential plasticization in low-speed crashes
Solution Approach 1:
The structural elements extend in the height direction (Z axis) to provide connection points at multiple vertical levels, transforming a single-plane connection into a three-dimensional load distribution system that reduces lever effects while maintaining compact installation space
3Adaptability or versatility
If deformation elements are varied up or down along the Z axis, then air inlet positioning requirements are met, but asymmetric load effects and incorrect crumpling behavior occur
Solution Approach 1:
The structural elements are designed with asymmetric positioning and dimensions to compensate for the asymmetric arrangement of deformation elements, creating a balanced load distribution system that ensures uniform crumpling behavior despite the asymmetric Z-axis positioning requirements for air inlets
Data Source
AI summary
A beam structure for a body of a motor vehicle includes at least two shock-absorbing beam elements, which extend substantially in a longitudinal direction and each have a first outer wall, a second outer wall running substantially parallel to the first outer wall, and an inner wall running substantially parallel to the first outer wall and to the second outer wall. At least one cross-beam extends substantially in a transverse direction running perpendicularly to the longitudinal direction, and is disposed at a first end of the shock-absorbing beam elements and is connected both to the first outer wall and to the second outer wall and/or the inner wall. At least two structure elements are respectively disposed at the first end of one of the shock-absorbing beam elements and are connected to the second outer wall and/or the inner wall of the shock-absorbing beam element in question and/or to the cross-beam.