Vehicle Front Side Frame Z-Shaped Folding Energy Absorption
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Solution Overview
Problem
Existing vehicle front structures fail to stably deform and absorb impact energy during collisions, as they lack a robust mechanism to distribute and manage collision loads effectively.
Innovation Solution
A vehicle front structure design featuring a side frame with an upper member bent downward to form a lower member, a bulkhead separating the closed cross-section of the lower member, and a fender support bracket to enhance the connection between the upper and lower members, allowing for controlled Z-shaped folding and efficient energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple bent side frame structure is used, then the device complexity is reduced, but the stability of deformation and energy absorption capability deteriorates
Solution Approach 1:
The side frame is segmented into upper and lower members connected by a bent part, and the closed cross section is divided into multiple compartments by bulkheads. This segmentation allows controlled deformation at specific locations while maintaining overall structural integrity and stable energy absorption.
Solution Approach 2:
Bulkheads are strategically placed at specific locations within the closed cross section to create compartments with different structural properties. The bent part connecting upper and lower members is designed with specific geometric features that promote stable Z-shaped folding. These local structural modifications enable controlled deformation patterns without requiring complete redesign of the entire structure.
2Reliability
If a complex bulkhead structure is added to separate the closed cross section, then the deformation stability is improved, but the device complexity increases
Solution Approach 1:
The closed cross section is divided into multiple compartments using bulkheads that extend partially across the section. This segmentation creates controlled deformation zones while maintaining structural integrity. The bulkheads are positioned to guide the folding pattern without requiring excessive structural complexity.
Solution Approach 2:
The bulkheads and bent part geometry are pre-designed to guide the deformation pattern before collision occurs. The Z-shaped folding path is predetermined by the structural configuration, ensuring stable and predictable energy absorption during impact without requiring active control mechanisms.
3Loss of energy
If the upper member is bent downward to form a lower member, then the energy absorption capability is improved, but the structural integrity may deteriorate
Solution Approach 1:
The bent part connecting upper and lower members is designed as a distinct structural element with optimized geometry. This segmentation allows the bent part to serve as a controlled deformation zone that absorbs energy through Z-shaped folding while the remaining portions of upper and lower members maintain their structural integrity.
Solution Approach 2:
The bent part geometry is pre-configured to promote stable folding patterns during impact. The angular configuration and dimensional proportions are designed in advance to ensure that when collision occurs, the deformation follows a predictable Z-shaped path that maximizes energy absorption while preserving the integrity of the overall side frame structure.
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 design enables stable deformation and effective absorption of impact energy by preventing undesirable folding of the upper bent part, maintaining structural integrity and enhancing energy absorption efficiency during collisions.
Implementation Method 1
a vehicle front structure which include a bent side frame, is deformed stably when collision load is applied, and stably absorb impact energy by the deformation
Data Source
AI summary
A side frame is arranged outward of a front side frame in a vehicle width direction. The side frame includes an upper member, and a lower member connected to a front end of the upper member and extending frontward and downward. An upper bent part bent frontward and upward is formed in a connection part between the upper member and the lower member. A bulkhead is provided frontward of the upper bent part so as to separate a closed cross section part of the lower member.