Technology of Front End Module to Automotive Vehicles 2003-01-3669

The front end module technology is a system developed to make the interface with vehicle body in accordance with costumer requirements. This modular system also has characteristics to reinforce the structure (chassis, main rails, shotguns), respecting its robustness (tolerances of the body) in accordance with NVH performance. The decision of having a FEM design made by steel and plastic was taken due to NVH specification, impact and safety requirements. Other items were either considered such as: fixation on the body of the vehicle, constraints between bumper beam and engine cooling module. Simulation tools including: durability test (static and dynamic) and modal F.E.A analysis, CAE system, crash test performance, aerodynamics required to insure results desired results. On the specification requirement for the front end module, testing is done to insure that the forces applied resist to vibrations, minor impact for low speed ( 4 to 8 Km/h ) meeting objectives without damaging the affected functions of the components. The frontal impact crash testing (speed between 56 to 65 Km/h) is evaluate in accordance with the design orientations based on customer recommendations. Some important points such as: to have a plane surface contact area during impact ( car to car ), to have better barrier topography, to avoid penetration point in the opposite vehicle, linearity of crash energy absorption, good distribution of stress on side members ( side rails ), avoid hood disengagement from the hood latch and component ejection are essential to define the front end module design, which has important influence on the vehicle design.