The incorporation of a Rear Underrun Protection Device (RUPD) is imperative to mitigate the risk of smaller vehicles becoming lodged beneath the rear-end of larger vehicles in the event of collisions. This project is dedicated to the meticulous design of an RUPD adhering to the standards set by Chinese regulatory authorities for vehicles classified under N2. Utilizing Computer-Aided Design (CAD) software, various design iterations were generated following a comprehensive review of existing models. The final design successfully meets all engineering specifications outlined by N2 classification standards, meeting the criteria established by our sponsors. A detailed Computer-Aided Engineering (CAE) analysis of the structure, particularly through two-point and three-point static loading tests, was conducted to validate the engineering specifications. Extensive research into material properties and costs for both the base material and anti-rust coating was undertaken to ensure the development of a functional prototype. The final prototype is manufactured using Mild Steel Q235, featuring anti-rust and anti-oxidation paint which allows it to seamlessly align with the Hummer's overall aesthetic. Additionally, it incorporates reflective film to enhance visibility in low-light conditions and rubber buffer pads in the corners to augment the protective functionality of the RUPD. This comprehensive approach ensures that the final design not only meets but exceeds the required standards, underscoring its efficacy in enhancing vehicular safety.
