All-aluminum alloy lightweight minibus structure

Abstract

The all-aluminum alloy lightweight minibus structure adopts a combined longitudinal beam type mortise and tenon cavity beam aluminum alloy frame, which realizes the assembly adaptability to various front and rear axles of different widths; adopts an aluminum alloy profile hard point structure, which realizes more effective hard point load bearing and significantly reduces the hard point manufacturing and assembly process and manufacturing cost; adopts an integrated design of a combined longitudinal beam and a battery compartment, which realizes high torsional stiffness of the frame and effective use of space; by improving the assembly structure between the side panel module and the frame module, the module assembly stiffness is improved and the module assembly process is simplified. The present invention provides an all-aluminum alloy, full-load, integrated lightweight structure solution for minibuses. The curb weight of a new energy minibus adopting this lightweight structure can be reduced by more than one third compared to a traditional new energy minibus of the same specification.

Description

Technical Field

[0001] The present invention relates to the technical field of new energy vehicle manufacturing, and in particular to an all-aluminum alloy lightweight minibus structure. Background Art

[0002] M3 minibuses (commonly known as minibuses) are buses with a length of about 6 meters, a passenger capacity of 20-30 people, and a body width of about 2 meters. They are a means of transportation for "microcirculation" in large cities, and are also an important means of transportation for small towns and even "village-to-village". The curb weight of traditional steel-structured new energy minibuses is about 4-5 tons, and the energy consumption is relatively high. In order to save energy, it is urgent to carry out lightweight design of minibuses. Aluminum alloy is an excellent lightweight material and has been applied in the body of buses, but the aluminum alloy of the frame has not achieved a breakthrough in application, and there is no all-aluminum alloy minibus in the market.

[0003] The following public documents on the aluminum alloy lightweight minibus body structure were found in the early stage of this patent:

[0004] 1. Lightweight bus frame; Application number: CN201110361350.7; Applicant: Dongguan Sanxin Electric Vehicle Technology Co., Ltd.; Abstract: Lightweight bus frame, including an annular frame surrounding the front, both sides and the rear of the vehicle, the annular frame is divided into a roof annular frame, a waist annular frame and a bottom annular frame, the waist annular frame is left empty at the door, and the bottom annular frame is arched upward at the wheel placement to accommodate the wheel; the roof is provided with a plurality of cross beams spanning between the two side frame edges of the roof annular frame, and a longitudinal beam is also provided to span these cross beams; the bottom of the vehicle is provided with a plurality of cross beams spanning between the two side frame edges of the bottom annular frame, and a longitudinal beam is also provided to span these cross beams; the front, both sides and the rear of the vehicle are all provided with a plurality of vertical beams spanning the above-mentioned annular frames; the above-mentioned annular frame is a profile beam, and the above-mentioned cross beams, longitudinal beams and vertical beams are all profile beams. The present invention has a firm structure, adopts profile beams and does not require too many connectors, and can simultaneously meet the requirements of lightweight, simplicity and safety.

[0005] 2. Automobile body transition structure; Application number: CN201210129441.2; Applicant: Dongguan Sun Yat-sen University Research Institute; Dongguan Sanxin Electric Vehicle Technology Co., Ltd.; Abstract: Automobile body transition structure, including connecting profile, grabbing profile and column grabbing head; the connecting profile includes a curved portion and grabbing portions located at both ends of the curved portion, the grabbing portion includes two side walls and a bottom wall connecting the two side walls, the two side walls are provided with grabbing hooks extending inwards, and the bottom wall is provided with T-shaped hooks; the present invention is used to connect two non-coplanar vehicle body walls, such as a roof and a side wall, or a front wall and a side wall adjacent to a vehicle body, and the assembly of the connecting profile, the grabbing profile and the column grabbing head is very convenient and rapid, and the installation can be completed by sliding the multiple T-shaped clamping structure along the groove, and the profile is light in weight and the multiple clamping structure is high in strength; the plug-in portion of the column grabbing head can be directly inserted into the cavity of the profile perpendicular to the grabbing profile, so that the vehicle body wall and the automobile body transition structure of the present invention are convenient and rapid to connect.

[0006] 3. A lightweight frame body with modular connection; Application number: CN201410021954.0; Applicant: Dongguan Sun Yat-sen University Research Institute; Dongguan Sanxin Electric Vehicle Technology Co., Ltd.; Abstract: A lightweight frame body with modular connection, including a chassis frame module, a body frame module and a roof frame module, each module is formed by a plurality of longitudinal beams and transverse beams mortise and tenoned with each other, the chassis frame module is provided with a plurality of plug-in sleeves, and the two sides of the roof frame module are connected with transfer beam structures, one end of the longitudinal beam of the body frame module is plugged with the plug-in sleeve of the chassis frame module, and the other end of the longitudinal beam of the body frame module is connected with the transfer beam structure; the longitudinal beam, transverse beam and transfer beam structure are all profile beams. Through the setting of the above-mentioned connection structure, the frame can be modularly designed, easy to manufacture and install, ensure installation accuracy, reduce production costs, and have a beautiful appearance, so that the frame can be lightweight while meeting safety standards.

[0007] 4. A front and rear face connection structure of a lightweight minibus and a body frame; Application number: CN201610610642.2; Applicant: Dongguan Sun Yat-sen University Research Institute; Dongguan Sanxin Electric Vehicle Technology Co., Ltd.; Abstract: A front and rear face connection structure of a lightweight minibus and a body frame, wherein the front face cover and the rear face cover of the automobile are respectively fixedly installed at the front end and rear end of the body connection end face frame through connecting burrs; The front and rear face connection structure of the present invention and the body frame have the following advantages: 1. The connecting burrs connected to the front and rear ends of the body connection end face frame provide a good connection structure for the front and rear face connection of the automobile, which is convenient for the assembly connection of the front and rear face of the automobile and the body frame, and the process is simple and the connection structure has high strength; 2. The connecting burrs can be used as a reinforcing rib structure of the front and rear end faces of the body connection end face frame, which greatly enhances the structural strength of the front and rear end faces of the body connection end face frame; 3. The front and rear faces using the connection structure and the body connection end face frame have better waterproof sealing; 4. The surfaces of the front and rear face covers are smoothly connected with the roof molding surface and the side surface.

[0008] 5. Full-load, modular, fully lightweight logistics vehicle structure and vehicle; Application number: CN201810986448.3; Applicant: Wuhan Intelligent Control Industrial Technology Research Institute Co., Ltd.; Huazhong University of Science and Technology; Abstract: A full-load, modular, fully lightweight logistics vehicle structure and vehicle, belonging to the field of automobile technology. The structure includes an aluminum alloy chassis structure, a side wall structure, a vertical partition surface structure, a front cabin instrument panel structure, a roof structure and a connecting rib. The aluminum alloy chassis structure includes a crossbeam. The side wall structure includes an outer frame upper side beam and an outer frame A-pillar. The side wall structure and the crossbeam are connected by mortise and tenon. The roof structure and the outer frame upper side beam are screwed or mortise and tenon connected. The vertical partition surface structure is connected to the side wall structure, chassis structure and ceiling structure respectively by mortise and tenon. The front cabin instrument panel structure is connected to the outer frame A-pillar by mortise and tenon. The front cabin instrument panel structure is threaded or welded to the chassis structure. The connecting ribs are connected to the aluminum alloy chassis structure, the side wall structure, the vertical partition surface structure, the front cabin instrument panel structure and the roof structure by mortise and tenon welding. The automobile includes the above structure. The structure has good mechanical properties and light weight. The automobile is easy to manufacture and assemble in modular form.

[0009] 6. An aluminum alloy side panel structure and automobile; Application number: CN201810986348.0; Applicant: Wuhan Intelligent Control Industrial Technology Research Institute Co., Ltd.; Abstract: An aluminum alloy side panel structure and automobile, belonging to the field of automobile lightweighting. The structure includes an outer frame upper side beam, an outer frame A-pillar, an outer frame C-pillar, an outer frame lower middle side beam, an outer frame lower front side beam, an outer frame lower rear side beam, an upper crossbeam, a lower crossbeam, a middle crossbeam, a door oblique beam, a plurality of columns and an internal plug-in joint. The plurality of columns are connected with the upper crossbeam, the lower crossbeam, the middle crossbeam, the door oblique beam, the outer frame upper side beam, the outer frame lower middle side beam, the outer frame lower front side beam, and the outer frame lower rear side beam by mortise and tenon. The upper crossbeam is connected with the end intersection of the outer frame A-pillar and the outer frame C-pillar by an internal plug-in joint mortise and tenon. One end of the lower crossbeam is connected with the door oblique beam by an internal plug-in joint mortise and tenon, and the other end of the lower crossbeam is connected with the outer frame C-pillar by an internal plug-in joint mortise and tenon. The outer frame lower front side beam and the outer frame A column, the outer frame A column and the outer frame upper side beam, the outer frame upper side beam and the outer frame C column, and the outer frame C column and the outer frame lower rear side beam are connected by an internal plug joint. The automobile includes the above structure. The structure and the automobile have good lightweight effect.

[0010] The above existing documents are all previous designs of the inventor, continuing the following three evolutionary routes:

[0011] 1) The degree of aluminum alloying gradually increases, and the lightweighting effect continues to improve: aluminum alloying of the vehicle body (References 1, 2, 3), aluminum alloying of the vehicle body + frame (4), aluminum alloying of the vehicle body + frame + hard point (5, 6). This evolutionary path reflects the law of aluminum alloy lightweighting progress from easy to difficult, from part to all; in other words, the earlier the literature, the less aluminum alloying rate and lightweighting effect.

[0012] 2) Continuously improve the mechanical properties of aluminum alloy structures: explore better and more reasonable internal module structures, hard point structures, and assembly structures between modules, and strive to improve the overall mechanical properties of the body structure. In other words, the above patents are still insufficient in mechanical properties and assembly performance. For example, the hard point solutions of Documents 5 and 6 use combined crossbeam hard points, which leads to a more complex structure, difficult assembly, and limited load-bearing capacity; the lateral stiffness and torsional stiffness of the frames of Documents 4, 5, and 6 are insufficient.

[0013] 3) Continuously simplify the manufacturing process and assembly process of modules: The aluminum alloy side panels and steel structure frames of References 1, 2, and 3 are connected by a plug-in sleeve, which is simple to assemble, but the assembly interface is a point-line interface, and the assembly stiffness of the side panels is limited. The aluminum alloy side panels and aluminum alloy frames of References 4, 5, and 6 are connected by a mortise and tenon structure, which realizes the planarization of the assembly interface and greatly improves the module assembly stiffness. However, the numerous mortise and tenon connections require the tenon and the mortise hole to be accurately aligned, which requires high preparation precision, and the fixing operation after alignment is relatively cumbersome. Summary of the invention

[0014] The all-aluminum alloy lightweight minibus structure of the present invention optimizes and improves the original lightweight minibus body structure, and redesigns the frame topology, hard point structure, battery compartment structure and layout space, longitudinal beam structure and profile cross-section of each rod, thereby achieving the advantages of improved body structure rigidity, optimized space layout, further reduced body weight, and more convenient body assembly.

[0015] To achieve the above object, the technical solution of the present invention is as follows:

[0016] The minibus is made of all-aluminum alloy and is lightweight. The body structure includes: a frame module, a side panel module, a roof module, a front compartment and a rear compartment. The side beams on the frame module are connected to the side panel bottom beams of the side panel modules. The upper, lower, left and right sides of the battery compartment on the frame module are connected to the side panel modules. The edge of the pedal structure on the frame is connected to the side panel modules. The side panel side beams at the upper end of the side panel modules are connected to the roof side longitudinal beams of the roof module.

[0017] The combined longitudinal beam in the frame module is composed of a front longitudinal beam and a rear longitudinal beam, which form an overlapping combined area. At least one battery compartment is arranged in the overlapping combined area and is connected to the front longitudinal beam and the rear longitudinal beam by mortise and tenon joints.

[0018] The outer surface of the battery compartment is connected to the side of the combined longitudinal beam through a flange edge, a plurality of frame cross beams are arranged laterally at the upper and lower parts of the frame, the frame cross beams are connected to the upper and lower cavities of the combined longitudinal beams through tenon joints, a plurality of small longitudinal beams are arranged longitudinally on the frame module, the small longitudinal beams are interlaced with the frame cross beams through mortise and tenon joints, and the small longitudinal beams are in contact with the surface of the battery compartment.

[0019] The side panel module includes a side panel edge beam, a side panel lower beam and a wheel frame to form an outer contour, a plurality of laterally connected waistline beams and a plurality of vertically connected side panel columns are arranged in the middle of the outer contour, glass is installed in the area between the straight rod portion of the side panel edge beam and the waistline beam, and a profile panel is installed in the area between the floor bottom beam and the waistline beam.

[0020] The cross-section of the side panel edge beam profile is a fan-shaped shape, and the side of the fan is arranged to connect the flash to form an L-angle mounting surface. The straight side beam of the top cover is installed and fixed on the L-angle mounting surface. Sealing glue is applied on the L mounting surface, and the side of the fan-shaped beam is fixed with bolts, and the flash surface is fixed with rivets; the side panel floor bottom beam and the lower bottom beam respectively form an L-angle mounting surface with the upper edge beam and the lower edge beam on the frame module, and are fixed with bolts on the side of the beam and rivets on the other side.

[0021] A profile panel is installed in a partial area between the floor bottom beam and the waistline cross beam, a supporting rib is horizontally arranged on the back of the profile panel, and a splicing groove and a splicing edge are arranged at the upper and lower ends of the profile panel.

[0022] The top cover module is composed of a frame surrounded by a top cover straight side beam and a top cover curved side beam. A number of top cover small longitudinal beams and top cover curved cross beams are arranged in parallel in the middle of the top cover module. The two ends of the top cover small longitudinal beam and the top cover curved side beam are a top-mounted mortise and tenon structure, the two ends of the top cover curved cross beam and the top cover straight side beam are a top-mounted mortise and tenon structure, and the intersection of the top cover curved cross beam and the top cover small longitudinal beam is a through-tenon structure; at the right angle where the top cover straight side beam and the top cover curved side beam are connected, two ends of an L-shaped connector are arranged to be inserted into the inner cavity of the above two for plugging and fixing.

[0023] The profile cross-section of the combined longitudinal beam is a vertical multi-cavity aluminum profile, which, from top to bottom, are respectively the first cavity, the second cavity, the third cavity, the fourth cavity, the fifth cavity and the sixth cavity; the middle of the profile cross-section of the leaf spring front support is a hollow cavity, a through hole for the leaf spring pin A is reserved in the middle of the hollow cavity, and a U-shaped clamping plate structure is formed at the upper and lower parts of the cavity to clamp the combined longitudinal beam, and the distance between the clamps matches the width of the combined longitudinal beam cross-section; an installation groove is processed on the part of the combined longitudinal beam profile where the leaf spring front support is installed, and in the installation groove, the upper and lower U-shaped clamping plate structures of the hollow cavity of the leaf spring front support respectively form U-shaped surface contacts with the third cavity and the fifth cavity of the longitudinal beam, and are fixed by glue and bolts.

[0024] The leaf spring rear support is fixedly installed on the combined longitudinal beam, and the cross-section of the leaf spring rear support profile is a U-shaped groove, and the spacing between the inner walls of the two sides of the groove is equal to the cross-section width of the combined longitudinal beam profile; the groove forms a U-shaped surface contact with the two sides of the combined longitudinal beam and the lower edge of the third cavity, and is fixed by glue and bolts, and through holes for the leaf spring pins B are set on both sides of the groove.

[0025] The shock absorber support is fixedly installed on the combined longitudinal beam, and the cross-section of the shock absorber support profile is an inverted F shape. The spacing between the two horizontal sides of the F shape matches the height spacing of the first cavity, and the two horizontal sides of the F shape respectively clamp the upper edge and the lower edge of the first cavity; a through hole for the shock absorber pin is arranged on the upper part of the vertical edge of the F shape, and the F shape forms surface contact with the side wall of the combined longitudinal beam and the upper and lower horizontal edges of the first cavity, and is fixed by glue and screws.

[0026] Advantages of the present invention:

[0027] The present invention has significant innovations in the three development paths of aluminum alloy lightweight structures;

[0028] 1) The combined longitudinal beam mortise and tenon cavity beam aluminum alloy frame can be adapted to the assembly of front and rear axles of different widths by simply adjusting the relative distance between the front and rear longitudinal beams;

[0029] 2) The aluminum alloy hardpoint structure is profiled and integrated with the beam structure, which brings the following advantages: the integration of the hardpoint and the beam improves the hardpoint bearing capacity and simplifies the hardpoint assembly process and leaf spring assembly process; the profiled hardpoint design greatly simplifies the hardpoint processing process and improves the material performance of the hardpoint;

[0030] 3) The integrated design of the combined longitudinal beam and the battery compartment takes advantage of the mechanical advantages of the beam and the large cavity, effectively improving the overall torsional stiffness of the frame. At the same time, the battery compartment is both the main load-bearing structure of the frame and the storage space for the battery, which improves the space utilization of the frame and provides an additional layer of external "armor" for the battery pack, improving the safety of the battery pack.

[0031] 4) Strengthen the connection rigidity between the frame and the side panel, and simplify the assembly process. First, the upper and lower connecting edges define the surface area assembly interface, and further increase the connection between the battery compartment end and the pedal boundary; second, the module assembly process is greatly simplified by bolting the connecting edges.

[0032] In short, based on previous practices, we have continuously explored and innovated to realize a new generation of all-aluminum alloy, full-load-bearing, integrated lightweight structural platform for minibuses, solving the core problem of all-aluminum alloy lightweight minibus structures and achieving comprehensive advantages such as good mechanical properties, light weight, strong adaptability, easy manufacturing and low cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 It is a structural diagram of the modules of the present invention;

[0034] Figure 2 This is the appearance structure diagram of the frame;

[0035] Figure 3 This is the appearance structure diagram of the combined longitudinal beam;

[0036] Figure 4 for Figure 2 The enlarged structure diagram at position Ⅰ in the middle;

[0037] Figure 5 This is a front view structural diagram of the side panel module;

[0038] Figure 6 for Figure 5 Middle AA section cross-section;

[0039] Figure 7 for Figure 6 The enlarged structural diagram at middle Ⅱ;

[0040] Figure 8 for Figure 6 The enlarged structural diagram at position Ⅲ in the middle;

[0041] Fig. 9 for Figure 6 The enlarged structural diagram at position IV in the middle;

[0042] Fig.10 for Figure 5 BB cross-section diagram;

[0043] Fig.11 for Figure 5 The CC cross-section diagram;

[0044] Fig.12 for Figure 5 DD cross-sectional view;

[0045] Fig.13 for Fig.12 Enlarged structural diagram at position V;

[0046] Fig.14 This is a top view of the top cover module;

[0047] Fig.15 for Fig.14 The enlarged structural diagram at VI in the middle;

[0048] Fig.16 for Fig.14 Middle EE section cross-section;

[0049] Fig.17 for Fig.16 The enlarged structural diagram at position VII in the middle;

[0050] Fig.18 This is a cross-sectional structural diagram of the leaf spring front support;

[0051] Fig.19 This is the appearance structure diagram of the leaf spring front support;

[0052] Fig. 20 It is a cross-sectional structural diagram of the leaf spring rear support;

[0053] Fig.21 This is the appearance structure diagram of the leaf spring rear support;

[0054] Fig. 22 This is a cross-sectional structural diagram of the shock absorber support;

[0055] Fig.23 This is the appearance structure diagram of the shock absorber support;

[0056] 1. Frame module; 11. Combined longitudinal beam; 111. Front longitudinal beam; 112. Rear longitudinal beam; 113. Connecting plug plate; 12. Small longitudinal beam; 13. Side beam; 131. Upper side beam; 132. Lower side beam; 14. Frame crossbeam; 15. Flange edge; 2. Side panel module; 21. Side panel side beam; 22. Side panel bottom beam; 221. Floor bottom beam; 222. Lower bottom beam; 23. Waistline crossbeam; 24. Side panel reinforcement beam; 25. Wheel frame; 26. Profile surface Plate; 27, side wall column; 28, side wall side beam insert; 29, end plug; 3, top cover module; 31, top cover straight side beam; 32, top cover bent side beam; 33, top cover small longitudinal beam; 34, top cover bent cross beam; 35, L-shaped connector; 4, battery compartment; 41, reinforced folding plate; 51, leaf spring front support; 511, leaf spring pin A; 52, leaf spring rear support; 521, leaf spring pin B; 53, shock absorber support; 531, shock absorber pin; 6, front compartment; 7, rear compartment. DETAILED DESCRIPTION

[0057] Example 1

[0058] The structure of the all-aluminum alloy lightweight minibus includes: a frame module 1, a side panel module 2, a roof module 3, a front compartment 6 and a rear compartment 7; the side beam 13 on the frame module 1 is connected to the side panel bottom beam 22 of the side panel module 2; the upper and lower left and right sides of the battery compartment 4 on the frame module 1 are connected to the side panel module 2; the edge of the pedal structure on the frame is connected to the side panel module 2; the side panel side beam 21 at the upper end of the side panel module is connected to the roof side longitudinal beam 31 of the roof module 3;

[0059] The combined longitudinal beam 11 in the frame module 1 is composed of a front longitudinal beam 111 and a rear longitudinal beam 112, which form an overlapping combination area, and at least one battery compartment 4 is arranged in the overlapping combination area and connected to the front longitudinal beam 111 and the rear longitudinal beam 112 by mortise and tenon joints;

[0060] The outer surface of the battery compartment 4 is connected to the side of the combined longitudinal beam 11 through a flange edge 15, a plurality of frame cross beams 14 are arranged transversely at the upper and lower parts of the frame, the frame cross beams 14 are connected to the upper and lower cavities of the combined longitudinal beams 11 through tenons, a plurality of small longitudinal beams 12 are arranged longitudinally on the frame module, the small longitudinal beams 12 are interlaced with the frame cross beams 14 through tenons, and the small longitudinal beams 12 are in contact with the surface of the battery compartment 4;

[0061] The side panel module 2 includes a side panel beam 21, a side panel lower beam 222 and a wheel frame 25 to form an outer contour, a plurality of waistline beams 23 connected laterally and a plurality of side panel columns 27 connected vertically are arranged in the middle of the outer contour, glass is installed in the area between the straight rod portion of the side panel beam 21 and the waistline beam 23, and a profile panel 26 is installed in the area between the floor bottom beam 221 and the waistline beam 23;

[0062] The side wall side beam 21 has a cross-section of a fan-shaped profile, and the side of the fan-shaped side is connected to the flash edge to form an L right-angle mounting surface. The top cover straight side beam 31 is installed and fixed on the L right-angle mounting surface. Sealing glue is applied on the L mounting surface, and bolts are used to fix the side of the fan-shaped beam, and rivets are used to fix the flash edge surface; the side wall floor bottom beam 221 and the lower bottom beam 222 respectively form an L right-angle mounting surface with the upper side beam 131 and the lower side beam 132 on the frame module 1, and are fixed on the side of the beam with bolts and fixed on the other side with rivets;

[0063] The floor beam 221 and the waistline beam 23 are partially installed in the area between the profile panel 26, the back of the profile panel 26 is provided with a transverse support rib, the upper and lower ends of the profile panel 26 are provided with splicing grooves and splicing edges;

[0064] The roof module 3 is composed of a frame surrounded by a roof straight side beam 31 and a roof curved side beam 32. A plurality of roof small longitudinal beams 33 and a roof curved cross beam 34 are arranged in parallel in the middle of the roof module 3. The two ends of the roof small longitudinal beam 33 and the roof curved side beam 32 are in a sleeve top mortise and tenon structure, the two ends of the roof curved cross beam 34 and the roof straight side beam 31 are in a sleeve top mortise and tenon structure, and the intersection of the roof curved cross beam 34 and the roof small longitudinal beam 33 is a through-tenon structure; at the right angle where the roof straight side beam 31 and the roof curved side beam 32 are connected, an L-shaped connector 35 is arranged at both ends to be inserted into the inner cavity of the above two for plugging and fixing;

[0065] The profile section of the combined longitudinal beam 11 is a vertical multi-cavity aluminum profile, which comprises the first cavity, the second cavity, the third cavity, the fourth cavity, the fifth cavity and the sixth cavity from top to bottom; the middle of the profile section of the leaf spring front support 51 is a hollow cavity, a through hole for the leaf spring pin A511 is reserved in the middle of the hollow cavity, and a U-shaped clamping plate structure is formed at the upper and lower parts of the cavity to clamp the combined longitudinal beam 11, and the distance between the clamping plates matches the cross-sectional width of the combined longitudinal beam 11; a mounting groove is machined on the part of the profile of the combined longitudinal beam 11 where the leaf spring front support 51 is installed, and in the mounting groove, the upper and lower U-shaped clamping plate structures of the hollow cavity of the leaf spring front support 51 respectively form U-shaped surface contacts with the third cavity and the fifth cavity of the longitudinal beam 11, and are fixed by glue and bolts;

[0066] The leaf spring rear support 52 is fixedly mounted on the composite longitudinal beam 11, and the cross-section of the leaf spring rear support 52 is a U-shaped groove, and the spacing between the inner walls of the two sides of the groove is equal to the cross-section width of the composite longitudinal beam 11; the groove forms a U-shaped surface contact with both sides of the composite longitudinal beam 11 and the lower edge of the third cavity, and is fixed by glue and bolts, and through holes for leaf spring pins B21 are set on both sides of the groove;

[0067] The shock absorber support 53 is fixedly installed on the combined longitudinal beam 11. The cross-section of the shock absorber support 53 is an inverted F-shape. The spacing between the two horizontal sides of the F-shape matches the height spacing of the first cavity. The two horizontal sides of the F-shape respectively clamp the upper edge and the lower edge of the first cavity. A through hole for the shock absorber pin 531 is provided on the upper part of the vertical side of the F-shape. The F-shape forms surface contact with the side wall of the combined longitudinal beam 11 and the upper and lower horizontal edges of the first cavity, and is fixed by glue and screws.

[0068] Application examples:

[0069] The entire vehicle profile is manufactured by extrusion of 6005A-T5 aluminum profiles. The frame of the all-aluminum minibus is 6 meters long, 2.5 meters wide, and 2.25 meters high. The weight of the aluminum frame is 590kg. The dynamic load-bearing capacity of the frame is greater than 4500kg, and the load-bearing capacity test complies with the national standard GBT6792-2009.

Claims

1. All-aluminum alloy lightweight minibus structure, characterized by: The vehicle body structure comprises: a frame module (1), a side panel module (2), a top cover module (3), a front compartment (6) and a rear compartment (7); the side panel beam (13) on the frame module (1) is connected to the side panel bottom beam (22) of the side panel module (2); the upper and lower left and right sides of the battery compartment (4) at both ends of the frame module (1) are connected to the side panel module (2); the edge of the pedal structure on the frame is connected to the side panel module (2); the side panel side beam (21) at the upper end of the side panel module is connected to the top cover straight side beam (31) of the top cover module (3); The combined longitudinal beam (11) in the frame module (1) is composed of a front longitudinal beam (111) and a rear longitudinal beam (112), the two forming an overlapping combined area, and at least one battery compartment (4) is arranged in the overlapping combined area and connected to the front longitudinal beam (111) and the rear longitudinal beam (112) by mortise and tenon joints; The outer surface of the battery compartment (4) is connected to the side of the combined longitudinal beam (11) through a flange edge (15); a plurality of frame cross beams (14) are arranged transversely at the upper and lower parts of the frame; the frame cross beams (14) are connected to the upper and lower cavities of the combined longitudinal beams (11) by tenon joints; a plurality of small longitudinal beams (12) are arranged longitudinally in the frame module; the small longitudinal beams (12) are interlaced with the frame cross beams (14) by tenon joints; and the small longitudinal beams (12) are connected to the surface of the battery compartment (4) by contact; The profile cross section of the combined longitudinal beam (11) is a vertical multi-cavity aluminum profile, which comprises a first cavity, a second cavity, a third cavity, a fourth cavity, a fifth cavity and a sixth cavity from top to bottom; the middle of the profile cross section of the leaf spring front support (51) is a hollow cavity, a through hole for a leaf spring pin A (511) is reserved in the middle of the hollow cavity, and a U-shaped clamping plate structure is formed at the upper and lower parts of the cavity to clamp the combined longitudinal beam (11), and the distance between the clamping plates matches the cross-sectional width of the combined longitudinal beam (11); a mounting groove is machined on the portion of the profile of the combined longitudinal beam (11) where the leaf spring front support (51) is mounted, and in the mounting groove, the upper and lower U-shaped clamping plate structures of the hollow cavity of the leaf spring front support (51) respectively contact the third cavity and the fifth cavity of the longitudinal beam (11) to form a U-shaped surface, and are fixed by glue and bolts.

2. The all-aluminum alloy lightweight minibus structure according to claim 1, characterized in that: The side panel module (2) comprises a side panel side beam (21), a side panel lower beam (222) and a wheel frame (25) to form an outer contour, a plurality of transversely connected waistline beams (23) and a plurality of vertically connected side panel columns (27) are arranged in the middle of the outer contour, glass is installed in the area between the upper straight rod portion of the side panel side beam (21) and the waistline beam (23), and a profile panel (26) is installed in the area between the floor bottom beam (221) and the waistline beam (23).

3. The all-aluminum alloy lightweight minibus structure according to claim 1, characterized in that: The side enclosure side beam (21) has a cross-section that is quasi-sector-shaped, and the side of the sector is connected to the flash edge to form an L-angle mounting surface. The top cover straight side beam (31) is mounted and fixed on the L-angle mounting surface. Sealing glue is applied to the L-mounting surface, and the side of the fan-shaped beam is fixed with bolts, and the surface of the flash edge is fixed with rivets. The side enclosure floor bottom beam (221) and the lower bottom beam (222) respectively form an L-angle mounting surface with the upper side beam (131) and the lower side beam (132) on the frame module (1), and are fixed with bolts on the side of the beam and rivets on the other side.

4. The all-aluminum alloy lightweight minibus structure according to claim 2, characterized in that: A profile panel (26) is installed in a partial area between the floor bottom beam (221) and the waistline cross beam (23), a support rib is transversely arranged on the back of the profile panel (26), and a splicing groove and a splicing edge are arranged at the upper and lower ends of the profile panel (26).

5. The all-aluminum alloy lightweight minibus structure according to claim 1, characterized in that: The roof module (3) is composed of a frame surrounded by a roof straight side beam (31) and a roof curved side beam (32). A plurality of roof small longitudinal beams (33) and a roof curved cross beam (34) are arranged in parallel in the middle of the roof module (3). The two ends of the roof small longitudinal beam (33) and the roof curved side beam (32) are in a mortise and tenon structure, the two ends of the roof curved cross beam (34) and the roof straight side beam (31) are in a mortise and tenon structure, and the intersection of the roof curved cross beam (34) and the roof small longitudinal beam (33) is a through-tenon structure. At the right angle where the roof straight side beam (31) and the roof curved side beam (32) are connected, an L-shaped connector (35) is arranged at both ends to be inserted into the inner cavity of the two for plugging and fixing.

6. The all-aluminum alloy lightweight minibus structure according to claim 1, characterized in that: The leaf spring rear support (52) is fixedly mounted on the combined longitudinal beam (11), and the profile section of the leaf spring rear support (52) is a U-shaped groove, and the spacing between the inner walls of the two side surfaces of the groove is equal to the width of the profile section of the combined longitudinal beam (11); the groove forms a U-shaped surface contact with the two sides of the combined longitudinal beam (11) and the lower edge of the third cavity, and is fixed by glue and bolts, and through holes for leaf spring pins B (521) are provided on the two side surfaces of the groove.

7. The all-aluminum alloy lightweight minibus structure according to claim 1, characterized in that: The shock absorber support (53) is fixedly mounted on the combined longitudinal beam (11), and the cross-section of the profile of the shock absorber support (53) is an inverted F-shape, the spacing between the two horizontal sides of the F-shape matches the height spacing of the first cavity, and the two horizontal sides of the F-shape respectively clamp the upper edge and the lower edge of the first cavity; a through hole for the shock absorber pin (531) is provided on the upper part of the vertical side of the F-shape, and the F-shape forms surface contact with the side wall of the combined longitudinal beam (11) and the upper and lower horizontal edges of the first cavity, and is fixed by glue and screws.

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