Vehicle Deformation Arrangement With Hinge-Limited Bending Moments
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Solution Overview
Problem
Conventional deformation arrangements for vehicles are complex to manufacture, often formed from different materials and components, and struggle to effectively limit bending moments during crashes.
Innovation Solution
A deformation arrangement featuring a one-piece, material-uniform contact element made of steel or aluminum alloy, which connects the deformation element to the vehicle longitudinal member, incorporating a deformable hinge region to absorb forces and limit bending moments during crashes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional deformation elements are used, then they can absorb crash forces, but they are complex to manufacture and cannot effectively limit bending moments
Solution Approach 1:
The contact element is designed as a one-piece component made from a single material (steel or aluminum alloy), merging multiple functions into one element. This single component provides both structural connection and controlled deformation capabilities, eliminating the need for multiple separate parts and complex assembly processes while effectively limiting bending moments through its integrated hinge region design
Solution Approach 2:
The deformable hinge region is designed with specific geometric parameters and material properties that enable controlled deformation at predetermined locations. By optimizing the hinge region's cross-sectional area, material distribution, and geometry, the contact element achieves effective bending moment limitation while maintaining manufacturing simplicity through standard fabrication processes
2Ease of manufacture
If conventional deformation elements made from different materials and components are used, then they can provide deformation capability, but they increase manufacturing complexity and costs
Solution Approach 1:
The contact element is manufactured as a one-piece component from a homogeneous material (either steel or aluminum alloy), ensuring uniform material properties throughout the structure. This homogeneity simplifies manufacturing processes by eliminating the need for joining different materials and components, while simultaneously improving reliability by ensuring consistent deformation behavior and structural connection performance throughout the entire contact element
3Productivity
If a one-piece contact element with deformable hinge region is used, then bending moments are effectively limited and manufacturing is simplified, but the deformable hinge region must be precisely designed
Solution Approach 1:
The deformable hinge region is designed with predetermined geometric features and cross-sectional characteristics that guide deformation to occur at specific locations during manufacturing. By pre-configuring the hinge region's geometry (such as reduced cross-sectional areas, fillet radii, or material distribution patterns), the design ensures that deformation occurs predictably during crashes, reducing the need for complex post-manufacturing adjustments while maintaining high manufacturing efficiency
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides an efficient and cost-effective structural connection that effectively limits bending moments, absorbs crash forces, and prevents damage to other vehicle components, while being easier to manufacture than conventional systems.
Implementation Method 1
the deformable hinge region is adapted to absorb, in the event of a crash, a force acting on the deformation element and displacing the deformation element at least partially by deforming the deformable hinge region
Implementation Method 2
the bending moment is limited by means of the internal friction of the deformable hinge region
Data Source
AI summary
The disclosure relates to a deformation arrangement for a vehicle, including a bumper cross member and a deformation element connected to the bumper cross member, where the deformation element has a deformation element end at a side facing away from the bumper cross member and a contact element having a first contact element part and a second contact element part, where the contact element has at least one deformable hinge region, which connects the second contact element part to the first contact element part, and where the deformable hinge region is adapted to absorb, in the event of a crash, a force acting on the deformation element and displacing the deformation element at least partially by deforming the deformable hinge region, and thereby causing a displacement and a pivoting of the second contact element part relative to the first contact element part.