Search Results

Modular front-end carriers to pre-assemble front-end components such as cooling systems, lights, and bumper beam have been in production in different vehicles for several years. Compression molded or overmolded steel/plastic carriers have traditionally been used. The present paper explains the design, material options, and engineering optimization of a composite front-end carrier, which utilizes long glass fiber injection moldable resins and adhesively bonded steel reinforcements. Experimental evaluation of prototypes shows the system met the functional performance requirements at minimum weight.

Automotive manufacturers are driving for improvement, creativity and innovation in vehicle systems in order to differentiate products in the global market. Progress in fuel efficiency, occupant safety, comfort, recyclable friendly pre-assembled modular systems, and novel manufacturing methods is difficult to achieve if no major departure from the traditional design, engineering, material mix, and assembly approaches is considered. More importantly, these benefits will not materialize unless the relationship between automotive manufacturers and suppliers changes, allowing suppliers to take a more active role in the vehicle development process. The present paper explores achievements made towards the development of new, innovative technologies to address simplification and overall performance improvements using non-traditional materials.

European car manufacturers and suppliers are currently stepping up the effort to develop solutions to meet pedestrian safety requirements, which will come into effect, starting in 2005. Numerous concepts, both active and passive, are being investigated to fulfil the pedestrian safety specifications, in addition to the many other limitations imposed on the front end of the car. All of them deal with the topic of energy absorption. Here, an approach to achieving a passive solution will be presented, describing the development of the ‘Virtual Stiffness Profile’ (VSP) to help identify the optimum balance of engineering and styling to meet the requirements. In this paper, specific emphasis is placed on the lower leg impact.