Vehicle Front Gusset Design for Offset Collision Energy Absorption
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Solution Overview
Problem
Existing vehicle body front structures face challenges in efficiently absorbing collision energy during narrow offset collisions due to non-uniform deformation and bending moments applied to bumper beam extensions and front side frames, which can lead to inadequate energy absorption and potential structural failure.
Innovation Solution
The vehicle body front structure incorporates gussets with higher strength than bumper beam extensions, positioned on the corners between bumper beam extensions and extension side mount members, to distribute and absorb collision loads, along with inclined front surfaces and closed cross-sections for enhanced rigidity, and uses side coupling members to reinforce gussets and distribute loads to front side frames and upper members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the bumper beam extension is designed to be compressed and deformed to absorb collision energy, then collision energy absorption is improved, but non-uniform compression and deformation occur due to bending moments, reducing structural reliability
Solution Approach 1:
The patent applies different strengths to different parts of the structure: the gusset is designed with higher strength than the bumper beam extension. This local differentiation allows the extension to deform and absorb energy while the gusset maintains structural integrity and prevents non-uniform deformation, resolving the contradiction between energy absorption and structural reliability.
2Loss of energy
If the front side frame is designed to be folded and deformed to absorb collision energy, then collision energy absorption is improved, but the influence of bending moments reduces deformation efficiency
Solution Approach 1:
The gusset acts as an intermediary element between the bumper beam extension and the front side frame. By positioning the gusset at the corner and designing it with higher strength, it mediates the force transmission, canceling the inward bending moment and allowing the front side frame to deform efficiently without the harmful influence of bending moments, thus improving deformation efficiency while maintaining energy absorption.
3Reliability
If gussets with higher strength than bumper beam extensions are added to cancel bending moments, then structural reliability is improved, but device complexity increases
Solution Approach 1:
The patent segments the corner connection into distinct functional elements: the bumper beam extension for energy absorption and the separately positioned gusset for structural support. This segmentation allows each component to perform its specific function optimally while maintaining overall structural reliability, with the gusset positioned at the corner between the extension and mount member.
4Force
If the gusset is positioned on the corner between bumper beam extension and extension side mount member, then load distribution is improved, but manufacturing precision requirements increase
Solution Approach 1:
The gusset is preliminarily positioned and joined to the bumper beam extension before final assembly with the extension side mount member. This preliminary positioning ensures accurate placement at the corner, improving load distribution while managing manufacturing precision requirements through a staged assembly process.
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
This configuration effectively cancels inward bending moments with outward bending moments, facilitates compressive and bending deformations, and enhances collision energy absorption, noise, and vibration performance by distributing loads efficiently across the structure.
Implementation Method 1
The bumper beam extension is a member that receives collision load and is compressed and deformed to thereby absorb the collision energy
Implementation Method 2
the collision load is applied to the gusset, and a bending moment toward the outside in the vehicle width direction (outward bending moment) thereby occurs to the bumper beam extension and the front side frame
Implementation Method 3
The collision load is applied to the gusset, and the bending moment toward the outside in the vehicle width direction (outward bending moment) thereby occurs to bend the bumper beam extension and the front side frame outward in the vehicle width direction via the gusset
Data Source
AI summary
A vehicle body front structure includes left and right extension side mount members that are provided at rear ends of left and right bumper beam extensions of a front bumper beam and left and right front side frames whose front ends are coupled with the left and right extension side mount members, respectively. The vehicle body front structure further includes left and right gussets that are positioned on left and right corners between outer surfaces in a vehicle width direction of rear end portions of the left and right bumper beam extensions and the left and right extension side mount members, respectively. The left and right gussets are joined to the left and right bumper beam extensions, respectively. Strength of the left and right gussets is higher than strength of the left and right bumper beam extensions.