Vehicle Frame Assembly Deformation Trigger Design
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Solution Overview
Problem
Vehicle frames designed on common platforms face variations in deformation characteristics due to differing engine sizes and components, which complicates the absorption of impact energy and accommodation of various vehicle components, such as those in electric vehicles, without compromising safety and structural integrity.
Innovation Solution
A frame assembly with a rail and bracket design that includes a deformation trigger, such as a divot, which allows controlled deformation during impacts, enabling the frame to absorb more energy while maintaining predictable deformation characteristics, and accommodating components of different sizes and weight distributions by attaching brackets on opposing sides of the deformation trigger.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a common frame design is used across different vehicle models, then manufacturing cost and platform sharing are improved, but deformation characteristics vary due to different engine sizes and components
Solution Approach 1:
The frame rail incorporates a deformation trigger at a specific location with different material properties (reduced thickness) compared to the rest of the rail. This local modification creates a predetermined deformation zone that ensures consistent deformation characteristics across different vehicle models despite variations in engine sizes and components.
Solution Approach 2:
The deformation trigger is pre-formed during manufacturing as a divot or reduced-thickness section in the frame rail. This preliminary structural feature ensures that during impact, deformation occurs at the predetermined location rather than varying based on different vehicle configurations, thus maintaining reliable deformation characteristics.
2Reliability
If the frame is designed to absorb more impact energy, then safety is improved, but the deformation characteristics become less predictable
Solution Approach 1:
The frame rail's thickness parameter is changed at the deformation trigger location, creating a localized weak point with reduced material thickness. This parameter change allows the frame to absorb more energy while ensuring deformation occurs at the predetermined location, maintaining predictable deformation characteristics.
3Adaptability or versatility
If larger components such as batteries and motors are installed in electric vehicles, then vehicle performance is improved, but the frame structure requires greater adaptability
Solution Approach 1:
The frame assembly with the deformation trigger serves multiple functions: it provides structural support, ensures predictable deformation during impact, and accommodates various vehicle components including larger battery and motor assemblies in electric vehicles. The bracket attachment system allows flexible component mounting while maintaining consistent safety characteristics.
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 frame assembly effectively absorbs impact energy and maintains consistent deformation characteristics across different vehicle models, allowing for the installation of larger components like batteries and motors while ensuring safety and structural integrity.
Implementation Method 1
the deformation characteristics of a common frame during a vehicle impact may vary depending on different engine sizes used in different models
Implementation Method 2
The deformation trigger may be a divot... The bracket may be designed to deform when the deformation trigger is in the deformed state
Data Source
AI summary
A frame assembly includes a rail including a straight portion, the straight portion including a first portion, a second portion, and a deformation trigger between the first and second portions, and a bracket attached to the first portion and the second portion.