Vehicle Load Introduction System with Deformation Modules

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Solution Overview

Problem

Existing load introduction systems in vehicles face challenges in managing tensile loadings during a central pillar crash, leading to increased costs, weight, and production complexity due to the need for stable designs that prevent component failure and interior penetration.

Innovation Solution

A load introduction system featuring left and right load supports connected to deformation modules, with a transverse crossmember that deforms and buckles inward upon impact, reducing tensile stresses and allowing for cost-effective and lightweight design by eliminating linear deformation and using a force-transmitting connection via an axis of rotation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a stable design with strong weld seams is selected to prevent body failure in central pillar crashes, then reliability is improved, but weight increases and manufacturing costs increase

Engineering Contradiction:

Improvebody stabilityVSAvoidvehicle weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The load introduction system is divided into separate functional components: deformation modules that absorb energy through controlled deformation, and a crossmember that transmits loads. This segmentation allows each component to be optimized for its specific function, reducing the need for over-engineered connections throughout the entire structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The crossmember acts as an intermediary element between the deformation modules and the vehicle body structure. It specifically manages tensile loadings by providing a dedicated load path, preventing these forces from being transmitted directly through weld seams to the bulkhead partition, thereby reducing connection requirements.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a stable design with strong weld seams is selected to prevent body failure in central pillar crashes, then reliability is improved, but manufacturing costs increase

Engineering Contradiction:

Improvebody stabilityVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The system segments the crash load management function into deformation modules and a crossmember, allowing for modular manufacturing and assembly. This reduces production complexity compared to manufacturing a single monolithic stable structure with extensive weld seams.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The crossmember serves as a specialized intermediary component that handles tensile loadings, allowing the main body structure to be designed with simpler, less expensive connections. This separation of functions reduces overall manufacturing costs by optimizing each component for its specific role.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Force

If linear deformation of central load supports is used to introduce load, then load introduction is achieved, but high tensile loadings occur requiring stable design

Engineering Contradiction:

Improveload introductionVSAvoidtensile loading

Core Design Contradiction:

ForceVSStress or pressure

Solution Approach 1:

The deformation modules are designed to undergo dynamic, non-linear deformation during impact rather than simple linear deformation. This allows the structure to adapt its deformation pattern based on the impact conditions, managing tensile loadings more effectively by distributing forces through controlled buckling and folding mechanisms.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The crossmember acts as an intermediary that specifically addresses tensile loadings generated during impact. It provides a dedicated load path for these tensile forces, separating them from the compression-dominated deformation modules, thereby reducing the stress requirements on individual components and their connections.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 system effectively absorbs crash loads, reduces tensile stresses, and prevents interior penetration, achieving stability and safety while minimizing weight and production costs, and enhancing fuel efficiency.

Implementation Method 1

The left load support is connected in a force-transmitting manner to a left deformation module on the left side of a front portion of the vehicle and the right load support is connected in a force-transmitting manner to a right deformation module on the right side of the front portion

Methodology Applied

Scientific EffectDeformation: Deformation

Implementation Method 2

a transverse crossmember that deforms and buckles inward upon impact

Methodology Applied

Scientific EffectBuckling:

Data Source

PatentUS10093256B2Vehicle load introduction system

Publication Date: 2018.10.09 DR ING H C F PORSCHE AG

AI summary

A load introduction system of a vehicle for introducing a load counter to the direction of travel of the vehicle includes a left load support on a left side of the vehicle and a right load support on a right side of the vehicle, wherein the left load support is connected in a force-transmitting manner to a left deformation module on the left side of a front portion of the vehicle and the right load support is connected in a force-transmitting manner to a right deformation module on the right side of the front portion. The load introduction system also includes a crossmember which extends transversely with respect to the direction of travel of the vehicle, wherein the crossmember is connected in a force-transmitting manner to the two deformation modules.