Vehicle Frame Diagonal Members Small Overlap Crash Force
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Solution Overview
Problem
In small overlap crashes, existing vehicle frames struggle to effectively manage impact energy, leading to cabin deformation and reduced seating space, as the crash force is not efficiently controlled, potentially failing to keep the vehicle away from the barrier.
Innovation Solution
A vehicle frame design featuring a pair of side frames, cross members, obliquely extending push members, first diagonal members, and a second diagonal member that disperses crash force to minimize deformation and push the vehicle sideways, utilizing a load path that includes these structural elements to maintain distance from the barrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crash force is utilized to push the vehicle sideways, then the vehicle can be kept away from the barrier, but the side frames deform and the pushing force is weakened
Solution Approach 1:
The vehicle frame is segmented into multiple functional components: push members for initial impact, first diagonal members for force transmission, second diagonal members for additional support, and cross members for structural reinforcement. This segmentation allows different parts to perform specific functions in the crash force management chain, preventing overall frame deformation while maintaining pushing capability.
Solution Approach 2:
The push members are designed to extend obliquely in both the front-rear direction and the vehicle width direction, creating a three-dimensional force transmission path. This oblique configuration allows the crash force to be distributed across multiple dimensions through the diagonal members, reducing concentrated stress on any single component while maintaining effective pushing force.
2Loss of energy
If crash force is weakened by side frame deformation, then energy is absorbed, but the force of pushing the vehicle sideways is also weakened
Solution Approach 1:
The first and second diagonal members act as intermediary elements between the push members and the side frames. These diagonal members transmit and distribute the crash force through a controlled load path, allowing energy absorption through structured deformation of the diagonal members themselves rather than through the side frames, thereby preserving the pushing force.
Solution Approach 2:
The diagonal members are positioned to change the load path parameters during collision. By obliquely extending from the push members to the side frames, they alter the force transmission angle and distribution, enabling controlled energy absorption while maintaining sufficient pushing force to keep the vehicle away from the barrier.
3Ease of manufacture
If a simple side frame structure is used, then manufacturing is easier, but crash force cannot be effectively controlled
Solution Approach 1:
The diagonal members serve multiple functions: they transmit crash force from the push members, provide additional structural support, and act as energy absorption elements. This multi-functionality allows the frame to achieve effective crash force control without adding excessive complexity, as the same components perform multiple roles in the crash management system.
Data Source
AI summary
A vehicle frame includes: a pair of right and left side frames; plural cross members connecting the pair of right and left side frames; and a pair of right and left push members obliquely extending forward and also toward the outside in the vehicle width direction, from right and left ends of one of the cross members in front of a cabin. The frame further includes: a pair of right and left first diagonal members obliquely extending backward from positions opposing the push members across one cross member to connect the one cross member with an intermediate portion of another cross member behind the one cross member; and a second diagonal member obliquely extending backward in V shape from a position opposing the first diagonal members across the other cross member to connect the other cross member with inner surfaces of the right and left side frames behind it.