Design Optimization of LCV CAB for Frontal Pendulum Test: Enhancing Survival Space Improvement Through Frugal Load Path Transfer Techniques

Abstract

In the fiercely competitive landscape of the automotive industry, Original Equipment Manufacturers (OEMs) encounter substantial challenges in the realm of Research and Development (R&D), particularly in the pursuit of lightweight design without compromising safety. As a result, the automotive sector continuously seeks innovative tools and methodologies to substantially optimize the structural composition of Light Commercial Vehicle (LCV) segments. The design of lightweight cabins, while simultaneously ensuring crashworthiness, not only plays a pivotal role in determining the market success of a new LCV but also holds significant legal implications. One well-established and indispensable evaluation tool to ascertain compliance with critical homologation requirements is the frontal pendulum test. This test serves as a litmus test for the appropriate design of Body in White (BIW) architecture, crucial for safeguarding occupant safety in unforeseen emergency scenarios.Within the context of adhering to styling themes and the design intent governing the three-dimensional (3D) geometry, a notable deviation emerged in the form of a 33 mm extension of the front panel in the newly stylized cabin. This deviation presented CAB engineers with a formidable challenge, as it disrupted the conventional load path of the frontal pendulum, rerouting it to the CAB itself instead of the intended transfer to the frame via the bull bar. The primary objective of this work is to restore the load path to the frame, all the while adhering to the original styling intent and refraining from introducing any additional modifications to major adjacent components such as the bumper and bumper reinforcement. Furthermore, this undertaking extends to encompass an exploration of cost reduction opportunities within the ambit of the newly styled CAB. Keywords: LCV CAB, Frontal Pendulum, Frugal Load, Occupant safety regulation, Styling impact, Pendulum impact, CAE simulation