Commercial vehicle tube beam assembly and manufacturing method thereof

Abstract

The present invention relates to the technical field of instrument panel tube beam assemblies, and in particular to commercial vehicle tube beam assemblies and their processing and manufacturing methods, comprising a hollow main circular tube beam, on which a central control lock mounting frame, a steering column fixing frame, and an instrument center main frame are integrally formed and bent in sequence from left to right, with intervals between them. The central control lock mounting frame, the steering column fixing frame, and the instrument center main frame are located on different planes; a central control lock bracket is detachably fixedly mounted on the central control lock mounting frame, and the central control lock bracket is used to provide installation support for the central control lock of a commercial vehicle. The central control lock mounting frame, the steering column fixing frame, and the instrument center main frame of the commercial vehicle tube beam assembly in the present invention are integrally formed by bending part of the hollow main circular tube beam structure, which can effectively ensure the integral formation of the entire frame body and improve the overall structural strength and anti-collision performance of the entire hollow main circular tube beam structure when used in conjunction with commercial vehicle instrument installation.

Description

Technical Field

[0001] The present invention relates to the technical field of instrument panel tube beam assemblies, in particular to a commercial vehicle tube beam assembly and a processing and manufacturing method thereof. Background Art

[0002] The instrument panel tube beam assembly is a framework component of the vehicle's safety system, which needs to transmit and absorb collision energy and loads and play a supporting role. It is the supporting skeleton of the instrument panel system and has a direct impact on the strength and appearance quality of the instrument panel system. The traditional instrument panel tube beam assembly is mainly composed of left and right side tube beam brackets, steering column fixing bracket assembly, panel mounting bracket, and round tube components.

[0003] Since commercial vehicles have higher comfort requirements than sedans, the most important structural component in the instrument panel system is the instrument panel tube beam assembly. After installation, it needs to provide support brackets for the instrument panel body, steering column, air conditioner and air duct, glove box, airbag, blower and other interior components.

[0004] The instrument panel tube beam assembly must possess sufficient rigidity to withstand the weight of the interior components mounted on it, as well as deformation caused by external forces. At the same time, its modal shape must be able to withstand vibrations from the road and engine to prevent resonance. Therefore, as a crucial component for enhancing the comfort and safety of the center console in a car, the instrument panel tube beam assembly is undergoing numerous innovations within the existing technology.

[0005] For example, in the patent document with patent application number CN201720235805.3, a patent technology with the patent name of: New automobile instrument panel tube beam assembly is disclosed, whose main structure includes a tube beam middle tube and a tube sleeve reinforcement rib wrapped around the outer periphery of the tube beam middle tube, and the left mounting bracket, relay mounting bracket, steering column reinforcement bracket, lower mounting bracket, instrument center main bracket, upper mounting bracket, airbag mounting bracket and right mounting bracket are installed on the tube sleeve reinforcement rib from left to right; the tube beam middle tube is made of aluminum-magnesium alloy material; the tube sleeve reinforcement rib, the left mounting bracket, the relay mounting bracket, the steering column reinforcement bracket, the lower mounting bracket, the instrument center main bracket, the upper mounting bracket, the airbag mounting bracket and the right mounting bracket are all made of nylon material.

[0006] It can be seen from the contents recorded in the above patent technology that the instrument panel tube beam assembly is mainly made of nylon material and is one-piece injection molded. It not only meets the requirements of lightweight tube beams, but also reduces the welding process and reduces labor intensity. However, when this structure is used to support the instrument panel of a commercial vehicle with a larger body volume, its support and load-bearing capabilities are difficult to meet the requirements, and its NVH performance is poor when encountering uneven road conditions. The noise, vibration and acoustic roughness treatment effects under complex road conditions are difficult to meet the standards.

[0007] To this end, the present invention proposes an instrument panel tube beam assembly structure suitable for commercial vehicles to better solve the problems existing in the prior art. Summary of the Invention

[0008] The present invention solves one of the above technical problems and adopts the following technical solution: a commercial vehicle tubular beam assembly includes a hollow main circular tubular beam, on which a central locking mounting frame, a steering column fixing frame, and an instrument center main frame are integrally formed and bent in sequence from left to right, with the central locking mounting frame, the steering column fixing frame, and the instrument center main frame being located on different planes;

[0009] A central lock bracket is detachably fixedly mounted on the central lock mounting base, and the central lock bracket is used to provide mounting support for the central lock of a commercial vehicle. A steering column bracket is detachably fixedly mounted on the steering column fixing base, and the steering column bracket is used to provide mounting support for the central lock of a commercial vehicle. An instrument central main bracket is detachably fixedly mounted on the instrument central main base, and the instrument central main bracket is used to provide mounting support for the central control unit of a commercial vehicle.

[0010] Lateral mounting brackets are fixedly mounted on the left and right ends of the hollow main circular tube beam respectively.

[0011] In any of the above schemes, it is preferred that a plurality of inner tube reinforcing sheet metal ribs are integrally formed on the inner wall of the central cavity of the hollow main circular tube beam, and each of the inner tube reinforcing sheet metal ribs is integrally formed with the hollow main circular tube beam.

[0012] In any of the above schemes, it is preferred that each bending portion of the hollow main circular tube beam is a rounded bend structure.

[0013] In any of the above schemes, it is preferred that a strengthening crossbeam sub-component is respectively inserted into the central cavity of the coaxially arranged straight pipe section of the hollow main circular tube beam, and the strengthening crossbeam sub-component is used to achieve structural reinforcement of the coaxially arranged straight pipe sections of the hollow main circular tube beam, and the two ends of the strengthening crossbeam sub-component respectively cooperate to pass through the preset mounting through holes at the outer ends of the corresponding bending parts on the hollow main circular tube beam and are respectively fixedly connected to the lateral mounting brackets at the corresponding positions.

[0014] In any of the above schemes, preferably, the contact areas between the outer side walls of the reinforcing cross beam sub-components at each of the mounting through holes and the outer side walls of the hollow main circular tube beam are fully welded.

[0015] In any of the above schemes, it is preferred that the reinforced crossbeam sub-component includes a horizontally arranged hollow auxiliary steel tube, and a plurality of injection-molded flow long holes are respectively provided on the outer side walls of the hollow auxiliary steel tube in each straight tube section coaxially arranged in the hollow main circular tube beam, and each of the injection-molded flow long holes respectively connects the through cavity of the hollow auxiliary steel tube with the central cavity between the two inner tube reinforcement sheet metal ribs of the hollow main circular tube beam at the corresponding position, and the inner end of each inner tube reinforcement sheet metal rib is respectively used to abut against the outer side wall of the hollow auxiliary steel tube.

[0016] In any of the above schemes, it is preferred that high-temperature rubber fluid is injection-molded into the through-cavity of the hollow secondary steel pipe. After the rubber fluid fills the through-cavity, it flows out from each injection-molded flow hole into the central cavity between the hollow secondary steel pipe and the hollow main circular tube beam and fills the central cavity. After the high-temperature rubber fluid cools and solidifies, an elastic connection matrix is ​​formed in the entire beam. The elastic connection matrix in the entire beam is used to fill the hollow space between the hollow secondary steel pipe and the hollow main circular tube beam and enhance its structural strength and anti-deformation ability.

[0017] In any of the above schemes, it is preferred that the outer walls of the hollow secondary steel pipes at the hollow cavities at the bending parts of the central control lock mounting frame, the steering column fixing frame, and the instrument central main frame are also provided with injection-molded flow long holes. When high-temperature rubber fluid is poured, it will fill the hollow cavities of the central control lock mounting frame, the steering column fixing frame, and the instrument central main frame and form an elastic support matrix for the frame after cooling and solidification.

[0018] In any of the above schemes, it is preferred that overflow holes connected to the internal central cavities are provided on the outer walls of the horizontal straight pipe sections at the ends of the central lock mounting base, the steering column fixing base, and the instrument central main base. When the central cavities at the corresponding positions are filled with high-temperature rubber fluid, continued pouring will cause the high-temperature rubber fluid to flow out of the overflow holes.

[0019] In any of the above schemes, it is preferred that both ends of the hollow main circular tube beam are evenly cut along its circumference and completely provided with several end connection parts, and each end connection part is bolted and fixed to the lateral mounting bracket at the corresponding position and fixed by welding at the abutment part.

[0020] The present invention also provides a method for processing and manufacturing the above-mentioned commercial vehicle tube beam assembly, comprising the following steps:

[0021] According to the drawings, straight tube blanks of hollow main round tube beams are manufactured by extrusion molding;

[0022] After the straight tube blanks of the hollow main round tube beams are extruded, the designated parts of the straight tube blanks are bent as needed to form the corresponding central lock mounting frame, steering column fixing frame, and instrument center main frame, so that the hollow main round tube beams form an integrated bent structure;

[0023] Four sections of 50-100 mm long are cut evenly along the circumference of each end of the hollow main circular tube beam, and the four sections of the cut tube wall are bent outward in sequence to form end connection parts;

[0024] After the above-mentioned hollow main circular tube beam is placed on the machining center and positioned using the tooling, each mounting through hole is machined at the bending portion where each coaxially arranged straight tube section of the hollow main circular tube beam is connected. During machining, each mounting through hole is controlled to maintain the coaxiality accuracy requirement with the central cavity of the hollow main circular tube beam, and the surrounding burrs of each mounting through hole are polished after the machining is completed;

[0025] Processing and strengthening the crossbeam sub-parts, after the hollow auxiliary steel pipe is placed on the CNC machine tool and clamped and positioned, each injection molding flow long hole is processed in its designated position in sequence, and the burrs of each injection molding flow long hole are polished;

[0026] Assemble the processed hollow secondary steel pipe and the hollow main circular tube beam to form a tube-beam assembly;

[0027] The resulting pipe-beam assembly is sent to a heat treatment process and high-temperature tempering is performed on the entire pipe-beam assembly and the weld area. The specific operation is as follows: the pipe-beam assembly is placed in a heat treatment furnace and heated to a temperature below Ac1 and then subjected to heat preservation treatment, so that plastic flow occurs in the pipe-beam assembly where the yield limit is reduced and the internal stress is high at high temperature. The elastic deformation gradually decreases, the plastic deformation gradually increases, and the stress is reduced. After the heat treatment, the pipe-beam assembly is removed and cooled;

[0028] Injection molding of the elastic connection matrix in the whole beam and the elastic support matrix of the chassis are completed in the tube-beam assembly;

[0029] Spraying an anti-corrosion coating on the outer surface of the pipe-beam assembly and completing the processing of the pipe-beam assembly after drying;

[0030] Install the central lock bracket, steering column bracket, and instrument center main bracket on the corresponding central lock mounting bracket, steering column fixing bracket, and instrument center main bracket in sequence;

[0031] Install the lateral mounting brackets and related accessories at both ends;

[0032] Check the connection strength of the assembly connection parts, and complete the assembly of the commercial vehicle tube beam assembly after passing the inspection;

[0033] Packing and shipping.

[0034] In any of the above solutions, preferably, the specific steps of completing the injection molding of the elastic connection matrix in the entire beam and the elastic support matrix of the chassis in the tube-beam assembly include:

[0035] Adjust the working position of the pipe-beam assembly, and then connect the ends of the cooled pipe-beam assembly to the external high-temperature injection molding pipeline; use high-pressure injection molding equipment to inject high-temperature rubber fluid from the ends of the hollow secondary steel pipes of the pipe-beam assembly;

[0036] The high-temperature flowing rubber fluid is controlled to fill the through cavities of the hollow secondary steel pipes in turn, and then the high-temperature flowing rubber fluid is continued to flow along each injection flow hole into the corresponding central cavity and complete the complete filling of each central cavity of the corresponding part;

[0037] Control the filling flow rate and speed, and observe the filling status. When the central cavity of each straight tube section of the hollow main circular tube beam is filled, the high-temperature flowing rubber fluid will overflow from both ends of the hollow main circular tube beam;

[0038] When the overflow holes of the central locking mounting frame, the steering column mounting frame, and the instrument panel center main frame are filled with high-temperature rubber fluid, the hollow cavities at the corresponding positions are fully filled.

[0039] After the injection molding is completed and the rubber fluid inside the tube-beam assembly is cooled, an elastic connection matrix inside the whole beam and an elastic support matrix of the chassis are formed at the corresponding positions;

[0040] Cut off the excess rubber overflowing from the pipe-beam assembly.

[0041] In any of the above solutions, preferably, the specific steps of assembling the hollow secondary steel pipe and the hollow main circular tube beam include:

[0042] The hollow main tube beam is transferred to the assembly station and horizontally positioned using a tool. A hollow auxiliary steel pipe that matches the hollow inner cavity is inserted from one end of the hollow main tube beam. Before installation, the end of the hollow auxiliary steel pipe is chamfered and polished to reduce assembly difficulty.

[0043] When the front end of the hollow auxiliary steel pipe reaches each installation through hole, the insertion speed is controlled and the circumferential direction is continuously adjusted to control the hollow auxiliary steel pipe to pass through each installation through hole in sequence, and finally to move out from the other end of the hollow main circular tube beam;

[0044] Rotate and adjust the hollow auxiliary steel pipe so that each injection flow hole is aligned with the corresponding central cavity and adjust it into place in the axial direction;

[0045] After adjustment, the two ends of the hollow auxiliary steel pipe are pre-fixed with the corresponding end contact parts of the hollow main circular tube beam by spot welding to prevent the relative displacement of the hollow auxiliary steel pipe and the hollow main circular tube beam;

[0046] The outer wall of the hollow secondary steel pipe at each installation hole is welded to the corresponding side wall joint of the hollow main circular tube beam, and full welding is used during welding to prevent leakage at the joint;

[0047] At this point, the hollow secondary steel pipe and the hollow main circular tube beam are assembled.

[0048] Compared with the prior art, the present invention has the following beneficial effects:

[0049] 1. The central locking mounting frame, steering column fixing frame, and instrument center main frame of the commercial vehicle tubular beam assembly of the present invention are integrally bent from part of the hollow main circular tubular beam structure, effectively ensuring the integral molding of the entire frame body and effectively improving the overall structural strength and anti-collision performance of the entire hollow main circular tubular beam structure when used in conjunction with commercial vehicle instrument installation.

[0050] 2. At the same time, considering the load resistance strength under the extreme load condition, a hollow secondary steel pipe is coaxially installed inside the hollow main circular tube beam to reinforce the structure of the hollow main circular tube beam as a crossbeam pipe fitting, so that it forms a tube-beam assembly, effectively ensuring the structural strength of the entire tube-beam assembly.

[0051] 3. The hollow structure of the tube-beam assembly composed of the hollow secondary steel pipe and the hollow main circular tube beam adopts high-temperature injection rubber to form the elastic connection matrix inside the whole beam and the elastic support matrix of the base frame, so that the entire tube-beam assembly forms a structural form that is soft inside and hard outside, and its deformation resistance when impacted is further enhanced. At the same time, due to the existence of the elastic connection matrix inside the whole beam and the elastic support matrix of the base frame, the deformation of the hollow main circular tube beam after impact can be effectively prevented; the deformation self-recovery ability of the entire tube-beam assembly structure is improved, and its deformation resistance and bending resistance are improved.

[0052] 4. The elastic connection matrix in each whole beam and the elastic support matrix of each chassis are integrally cast. Therefore, after being formed, the elastic connection matrix in the whole beam and the elastic support matrix of the chassis form a whole inside the central cavity and the through cavity, which can effectively prevent relative rotation between the hollow secondary steel pipe and the hollow main circular tube beam, and ensure the internal stability of the entire tube-beam assembly structure.

[0053] 5. At the same time, since the elastic connection matrix in the whole beam is filled and solidified in the central cavity between the adjacent inner tube reinforcement sheet metal ribs, the elastic connection matrix in the whole beam after forming can further realize the circumferential limitation of the hollow auxiliary steel pipe and the hollow main circular tube beam, effectively forming a rigid and flexible overall structure of the hollow auxiliary steel pipe, the hollow main circular tube beam, the elastic connection matrix in the whole beam, and the elastic support matrix of each chassis, ensuring the load resistance of the entire tube beam assembly when it is hit. At the same time, due to the presence of the rubber material of the elastic connection matrix in the whole beam and the elastic support matrix of each chassis as a buffer, it can play a role in vibration reduction and noise reduction, effectively improving the NVH performance of the commercial vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0054] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following briefly describes the drawings required for the specific embodiments or the description of the prior art. Similar elements or components are generally identified by similar reference numerals throughout the drawings. Elements or components in the drawings are not necessarily drawn to scale.

[0055] Figure 1 It is a structural schematic diagram of the present invention.

[0056] Figure 2 This is a schematic diagram of the three-dimensional structure of the present invention after removing the lateral mounting brackets at both ends.

[0057] Figure 3 for Figure 2 Schematic diagram of the main structure after removing the central locking bracket, steering column bracket, and instrument center main bracket.

[0058] Figure 4 for Figure 3 Schematic diagram of the right view structure.

[0059] Figure 5 It is a schematic structural diagram of the hollow main circular tube beam of the present invention after bending and forming.

[0060] Figure 6 It is a schematic diagram of the three-dimensional structure after the hollow secondary steel pipe is installed in the hollow main circular tube beam of the present invention.

[0061] Figure 7 for Figure 6 Schematic diagram of the local structure.

[0062] Figure 8 It is a partial cross-sectional structural schematic diagram of the present invention.

[0063] In the figure, 1. Hollow main circular tube beam; 101. Central cavity; 102. Inner tube reinforcement sheet metal ribs; 103. Rounded bend structure; 104. Straight tube section; 105. Mounting through hole; 2. Central lock mounting base; 3. Steering column fixing base; 4. Instrument central main base; 5. Central lock bracket; 6. Steering column bracket; 7. Instrument central main bracket; 8. Lateral mounting bracket; 9. Injection molded flow long hole; 10. Through cavity; 11. Elastic connection base in the whole beam; 12. Elastic support base of the base frame; 13. Overflow hole; 14. End connection part; 15. Hollow secondary steel pipe. DETAILED DESCRIPTION

[0064] The following embodiments of the technical solution of the present invention are described in detail with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention and are therefore only used as examples and are not intended to limit the scope of protection of the present invention. Figure 1-8 As shown in .

[0065] Example 1: A commercial vehicle tube beam assembly includes a hollow main circular tube beam 1, on which a central control lock mounting base 2, a steering column fixing base 3, and an instrument central main base 4 are integrally formed and bent from left to right, and the central control lock mounting base 2, the steering column fixing base 3, and the instrument central main base 4 are located on different planes; a central control lock bracket 5 is detachably fixedly installed on the central control lock mounting base 2, and the central control lock bracket 5 is used to provide installation support for the central control lock of the commercial vehicle; a steering column bracket 6 is detachably fixedly installed on the steering column fixing base 3, and the steering column bracket 6 is used to provide installation support for the central control lock of the commercial vehicle; an instrument central main bracket 7 is detachably fixedly installed on the instrument central main base 4, and the instrument central main bracket 7 is used to provide installation support for the central control unit of the commercial vehicle; side mounting brackets 8 are fixedly installed on the left and right ends of the hollow main circular tube beam 1 respectively. The central lock mounting base 2, steering column fixing base 3 and instrument central main base 4 in the present invention are all formed by bending the hollow main circular tube beam 1 to form the corresponding base frame parts. The entire hollow main circular tube beam 1 and the central lock mounting base 2, steering column fixing base 3 and instrument central main base 4 are formed as a single pipe fitting in one piece, which can effectively reduce the welds at the welding points, effectively improve the structural strength of each base frame support part, and effectively ensure the structural strength and load resistance of the entire pipe beam assembly after being installed at the front end of the dashboard in the later stage; in addition, since the central lock mounting base 2, steering column fixing base 3 and instrument central main base 4 are an integrated structure, when the central lock bracket 5, steering column bracket 6 and instrument central main bracket 7 are installed thereon, the base frame can be used as the main support and the bracket can be used as the auxiliary support. At the same time, each bracket can also be temporarily or on-site installed according to installation needs, and brackets of different sizes can be installed as needed, and the overall versatility is strong; the lateral mounting brackets 8 at the left and right ends of the hollow main circular tube beam 1 are convenient for connection with the corresponding parts of the overall frame of the commercial vehicle during later installation.

[0066] In any of the above schemes, it is preferred that a plurality of inner tube reinforcing sheet metal ribs 102 are integrally formed on the inner wall of the central cavity 101 of the hollow main circular tube beam 1, and each of the inner tube reinforcing sheet metal ribs 102 is integrally formed with the hollow main circular tube beam 1. The inner tube reinforcing sheet metal ribs 102 integrally formed on the inner side of the hollow main circular tube beam 1 have three functions. First, they can act as reinforcing ribs to effectively ensure the structural strength of the entire hollow main circular tube beam 1; second, the adjacent inner tube reinforcing sheet metal ribs 102 cooperate to separate the central cavity 101 and play a limiting role. When the hollow secondary steel pipe 15 is inserted and assembled, each inner tube reinforcing sheet metal rib 102 can tighten and limit the outer wall of the hollow secondary steel pipe 15; third, when the elastic connection matrix 11 in the whole beam is poured into the interior, each inner tube reinforcing sheet metal rib 102 acts like a limiting tooth to separate the entire central cavity 101 into four fan-shaped cavities and connect them with the through inner cavity of the hollow secondary steel pipe 15, and finally realize that the elastic connection matrix 11 in the entire beam stably connects the hollow main circular tube beam 1 and the hollow secondary steel pipe 15 into a whole.

[0067] In any of the above schemes, it is preferred that a strengthening crossbeam sub-component is respectively inserted into the central cavity 101 of the coaxially arranged straight pipe section 104 of the hollow main circular tube beam 1, and the strengthening crossbeam sub-component is used to achieve structural reinforcement of each coaxially arranged straight pipe section 104 of the hollow main circular tube beam 1, and the two ends of the strengthening crossbeam sub-component respectively cooperate to pass through the preset mounting through holes 105 at the outer ends of the corresponding bending parts on the hollow main circular tube beam 1 and are respectively fixedly connected to the lateral mounting bracket 8 at the corresponding positions.

[0068] The reinforcing crossbeam sub-components set here have two main functions. One is: it is inserted into the central inner cavity of the hollow main circular tube beam 1 to realize the center reinforcement of the hollow main circular tube beam 1 and improve the overall rigid strength and impact load resistance; the second is to provide a channel for the casting molding of the elastic connection matrix 11 in the whole beam, and promote the formation of the final rigid-flexible four-layer structure, from the inside to the outside, respectively, the rigid layer of the hollow main circular tube beam 1, the elastic connection matrix 11 layer in the outer whole beam, the rigid layer in the hollow auxiliary steel pipe 15, and the elastic connection matrix 11 layer in the center part of the whole beam that passes through the cavity 10. The four-layer sandwich structure composed of rigid and flexible structures can effectively ensure the rigid strength of the entire structure. At the same time, the two layers of elastic connection matrix 11 in the whole beam can provide flexible elastic support for the rigid layer, thereby effectively ensuring the rigid support and flexible reset performance of the entire structure, effectively reducing the deformation problem of the hollow main circular tube beam 1 caused by impact, and improving its self-reset ability.

[0069] In any of the above schemes, it is preferred that the reinforced crossbeam sub-component includes a horizontally arranged hollow auxiliary steel pipe 15, and a plurality of injection-molded flow long holes 9 are respectively provided on the outer wall of the hollow auxiliary steel pipe 15 in each coaxially arranged straight pipe section 104 of the hollow main circular tube beam 1, each of the injection-molded flow long holes 9 respectively connects the through cavity 10 of the hollow auxiliary steel pipe 15 with the central cavity 101 between the two inner tube reinforcement sheet metal ribs 102 of the hollow main circular tube beam 1 at the corresponding position, and the inner end of each inner tube reinforcement sheet metal rib 102 is used to abut against the outer wall of the hollow auxiliary steel pipe 15. The hollow secondary steel tube 15 inserted into the hollow main circular tube beam 1 can play the role of central reinforcement of the entire hollow main circular tube beam 1. At the same time, under the action of the four circumferential inner tube reinforcing sheet metal ribs 102, the circumferential limitation of the hollow secondary steel tube 15 can be achieved. At the same time, a space is formed between the hollow secondary steel tube 15 and the central cavity 101 of the hollow main circular tube beam 1, thereby ensuring that space is provided when pouring high-temperature rubber fluid in the later stage, ensuring that the rubber fluid can fully fill the spatial structure and form an integrally injection-molded rubber elastic structure.

[0070] In any of the above schemes, it is preferred that high-temperature rubber fluid is injection-molded into the through cavity 10 of the hollow secondary steel tube 15. After the rubber fluid fills the through cavity 10, it flows out from each injection flow hole 9 into the central cavity 101 between the hollow secondary steel tube 15 and the hollow main circular tube beam 1 and fills the central cavity 101. After the high-temperature rubber fluid cools and solidifies, an elastic connecting matrix 11 is formed in the entire beam. The elastic connecting matrix 11 in the entire beam is used to fill the hollow space between the hollow secondary steel tube 15 and the hollow main circular tube beam 1 and enhance its structural strength and anti-deformation ability. During the pouring process, each injection molded flow hole 9 can play the role of diverting overflow. Through the connecting effect of the injection molded flow hole 9, the through cavity 10 can be connected with the central cavity 101 of each hollow main circular tube beam 1 outside, and the flowing rubber fluid can flow quickly into the central cavity 101 of the hollow main circular tube beam 1, and finally the entire hollow secondary steel pipe 15 and the hollow main circular tube beam 1 are combined with the rubber structure to form the above-mentioned rigid-flexible four-layer structure, thereby improving the rigidity strength of the entire structure and the anti-deformation and reset capabilities after load impact, thereby ensuring the mechanical properties of the entire structure.

[0071] In any of the above schemes, it is preferred that the outer wall of the hollow secondary steel pipe 15 at the hollow cavities at the bending parts of the central control lock mounting frame 2, the steering column fixing frame 3, and the instrument central main frame 4 is also provided with injection-molded flow long holes 9. When the high-temperature rubber fluid is poured, it will fill the hollow cavities of the central control lock mounting frame 2, the steering column fixing frame 3, and the instrument central main frame 4 and form a frame elastic support base 12 after cooling and solidification. Here, the internal central cavity 101 of the central lock mounting frame 2, the steering column fixing frame 3, and the instrument center main frame 4 is also used to guide the high-temperature rubber fluid through the injection-molded flow long holes 9 at the corresponding positions, and finally the rubber fluid can be filled into the central cavity 101 at each frame position, so that a frame elastic support matrix 12 can be formed inside each central cavity 101 to achieve a support structure of a double-layer instrument support part that is rigid on the outside and soft on the inside. Since each frame is only used to support the instrument panel components, it is set as a double-layer structure without the need to add reinforcing crossbeam components. At the same time, since each frame is an integrated structure formed with the hollow main circular tube beam 1, its overall structural strength can be guaranteed, and the load-bearing performance of each frame structure can be effectively guaranteed. Its overall anti-deformation performance and load-bearing performance are significantly better than those of the traditional welded frame, and the effect of the entire tube beam assembly when installing the instrument panel components is better guaranteed.

[0072] Example 2: A commercial vehicle tubular beam assembly includes a hollow main circular tubular beam 1, on which a central locking mounting frame 2, a steering column fixing frame 3, and an instrument center main frame 4 are integrally formed and bent in sequence from left to right, with the central locking mounting frame 2, the steering column fixing frame 3, and the instrument center main frame 4 being located on different planes.

[0073] A central lock bracket 5 is detachably fixedly mounted on the central lock mounting base 2, and the central lock bracket 5 is used to provide mounting support for the central lock of a commercial vehicle. A steering column bracket 6 is detachably fixedly mounted on the steering column fixing base 3, and the steering column bracket 6 is used to provide mounting support for the central lock of a commercial vehicle. An instrument central main bracket 7 is detachably fixedly mounted on the instrument central main base 4, and the instrument central main bracket 7 is used to provide mounting support for the central control unit of a commercial vehicle.

[0074] Lateral mounting brackets 8 are fixedly mounted on the left and right ends of the hollow main circular tube beam 1 .

[0075] The processing of the commercial vehicle tube beam assembly is different from the traditional tube beam structure that mainly relies on welding. The central control lock mounting frame 2, the steering column fixing frame 3, and the instrument center main frame 4 in the present invention are all formed by bending the hollow main round tube beam 1 to form the corresponding frame parts. The entire hollow main round tube beam 1 and the central control lock mounting frame 2, the steering column fixing frame 3, and the instrument center main frame 4 are formed as a single pipe. It can effectively reduce the weld seams at the welding points, effectively improve the structural strength of each frame support part, and effectively ensure the structural strength and Load-bearing capacity; in addition, since the central lock mounting base 2, the steering column fixing base 3, and the instrument central main base 4 are an integrated structure, the base can be used as the main support and the bracket as the auxiliary support when installing the central lock bracket 5, the steering column bracket 6, and the instrument central main bracket 7 thereon. At the same time, each bracket can also be temporarily or on-site installed according to installation needs. At the same time, brackets of different sizes can be installed as needed, and the overall versatility is strong; the lateral mounting brackets 8 at the left and right ends of the hollow main circular tube beam 1 are convenient for connection with the corresponding parts of the overall frame of the commercial vehicle during later installation.

[0076] In any of the above schemes, it is preferred that a plurality of inner tube reinforcing sheet metal ribs 102 are integrally formed on the inner wall of the central cavity 101 of the hollow main circular tube beam 1, and each of the inner tube reinforcing sheet metal ribs 102 is integrally formed with the hollow main circular tube beam 1.

[0077] The inner tube reinforcing sheet metal ribs 102 integrally formed on the inner side of the hollow main circular tube beam 1 have three functions. First, they can act as reinforcing ribs to effectively ensure the structural strength of the entire hollow main circular tube beam 1; second, the adjacent inner tube reinforcing sheet metal ribs 102 cooperate to separate the central cavity 101 and play a limiting role. When the hollow secondary steel pipe 15 is inserted and assembled, each inner tube reinforcing sheet metal rib 102 can tighten and limit the outer wall of the hollow secondary steel pipe 15; third, when the elastic connection matrix 11 in the whole beam is poured into the interior, each inner tube reinforcing sheet metal rib 102 acts like a limiting tooth to separate the entire central cavity 101 into four fan-shaped cavities and connect them with the through inner cavity of the hollow secondary steel pipe 15, and finally realize that the elastic connection matrix 11 in the entire beam stably connects the hollow main circular tube beam 1 and the hollow secondary steel pipe 15 into a whole.

[0078] In any of the above schemes, it is preferred that each bending portion of the hollow main circular tube beam 1 is a rounded bending structure 103.

[0079] The rounded bend structure 103 can ensure a smooth transition of the bend, reduce the residual stress of the connection part, and improve the structural strength of the bend.

[0080] In any of the above schemes, it is preferred that a strengthening crossbeam sub-component is respectively inserted into the central cavity 101 of the coaxially arranged straight pipe section 104 of the hollow main circular tube beam 1, and the strengthening crossbeam sub-component is used to achieve structural reinforcement of each coaxially arranged straight pipe section 104 of the hollow main circular tube beam 1, and the two ends of the strengthening crossbeam sub-component respectively cooperate to pass through the preset mounting through holes 105 at the outer ends of the corresponding bending parts on the hollow main circular tube beam 1 and are respectively fixedly connected to the lateral mounting bracket 8 at the corresponding positions.

[0081] The reinforcing crossbeam sub-components set here have two main functions. One is: it is inserted into the central inner cavity of the hollow main circular tube beam 1 to realize the center reinforcement of the hollow main circular tube beam 1 and improve the overall rigid strength and impact load resistance; the second is to provide a channel for the casting molding of the elastic connection matrix 11 in the whole beam, and promote the formation of the final rigid-flexible four-layer structure, from the inside to the outside, respectively, the rigid layer of the hollow main circular tube beam 1, the elastic connection matrix 11 layer in the outer whole beam, the rigid layer in the hollow auxiliary steel pipe 15, and the elastic connection matrix 11 layer in the center part of the whole beam that passes through the cavity 10. The four-layer sandwich structure composed of rigid and flexible structures can effectively ensure the rigid strength of the entire structure. At the same time, the two layers of elastic connection matrix 11 in the whole beam can provide flexible elastic support for the rigid layer, thereby effectively ensuring the rigid support and flexible reset performance of the entire structure, effectively reducing the deformation problem of the hollow main circular tube beam 1 caused by impact, and improving its self-reset ability.

[0082] In any of the above solutions, it is preferred that the contact areas between the outer wall of the reinforcing crossbeam sub-component at each of the mounting through holes 105 and the outer wall of the hollow main circular tube beam 1 are fully welded.

[0083] The main purpose of full welding at the connection seams is to prevent leakage, which can ensure that leakage can be prevented during the subsequent high-temperature rubber fluid pouring and ensure the effect of pouring inside the cavity.

[0084] In any of the above schemes, it is preferred that the reinforced crossbeam sub-component includes a horizontally arranged hollow auxiliary steel pipe 15, and a plurality of injection-molded flow long holes 9 are respectively provided on the outer wall of the hollow auxiliary steel pipe 15 in each coaxially arranged straight pipe section 104 of the hollow main circular tube beam 1, each of the injection-molded flow long holes 9 respectively connects the through cavity 10 of the hollow auxiliary steel pipe 15 with the central cavity 101 between the two inner tube reinforcement sheet metal ribs 102 of the hollow main circular tube beam 1 at the corresponding position, and the inner end of each inner tube reinforcement sheet metal rib 102 is used to abut against the outer wall of the hollow auxiliary steel pipe 15.

[0085] The hollow secondary steel tube 15 inserted into the hollow main circular tube beam 1 can play the role of central reinforcement of the entire hollow main circular tube beam 1. At the same time, under the action of the four circumferential inner tube reinforcing sheet metal ribs 102, the circumferential limitation of the hollow secondary steel tube 15 can be achieved. At the same time, a space is formed between the hollow secondary steel tube 15 and the central cavity 101 of the hollow main circular tube beam 1, thereby ensuring that space is provided when pouring high-temperature rubber fluid in the later stage, ensuring that the rubber fluid can fully fill the spatial structure and form an integrally injection-molded rubber elastic structure.

[0086] In any of the above schemes, it is preferred that high-temperature rubber fluid is injection-molded into the through cavity 10 of the hollow secondary steel tube 15. After the rubber fluid fills the through cavity 10, it flows out from each injection flow hole 9 into the central cavity 101 between the hollow secondary steel tube 15 and the hollow main circular tube beam 1 and fills the central cavity 101. After the high-temperature rubber fluid cools and solidifies, an elastic connecting matrix 11 is formed in the entire beam. The elastic connecting matrix 11 in the entire beam is used to fill the hollow space between the hollow secondary steel tube 15 and the hollow main circular tube beam 1 and enhance its structural strength and anti-deformation ability.

[0087] During the pouring process, each injection molded flow hole 9 can play the role of diverting overflow. Through the connecting effect of the injection molded flow hole 9, the through cavity 10 can be connected with the central cavity 101 of each hollow main circular tube beam 1 outside, and the flowing rubber fluid can flow quickly into the central cavity 101 of the hollow main circular tube beam 1, and finally the entire hollow secondary steel pipe 15 and the hollow main circular tube beam 1 are combined with the rubber structure to form the above-mentioned rigid-flexible four-layer structure, thereby improving the rigidity strength of the entire structure and the anti-deformation and reset capabilities after load impact, thereby ensuring the mechanical properties of the entire structure.

[0088] In any of the above schemes, it is preferred that the outer wall of the hollow secondary steel pipe 15 at the hollow cavities at the bending parts of the central control lock mounting frame 2, the steering column fixing frame 3, and the instrument central main frame 4 is also provided with injection-molded flow long holes 9. When the high-temperature rubber fluid is poured, it will fill the hollow cavities of the central control lock mounting frame 2, the steering column fixing frame 3, and the instrument central main frame 4 and form a frame elastic support base 12 after cooling and solidification.

[0089] Here, the internal central cavity 101 of the central lock mounting frame 2, the steering column fixing frame 3, and the instrument center main frame 4 is also used to guide the high-temperature rubber fluid through the injection-molded flow long holes 9 at the corresponding positions, and finally the rubber fluid can be filled into the central cavity 101 at each frame position, so that a frame elastic support matrix 12 can be formed inside each central cavity 101 to achieve a support structure of a double-layer instrument support part that is rigid on the outside and soft on the inside. Since each frame is only used to support the instrument panel components, it is set as a double-layer structure without the need to add reinforcing crossbeam components. At the same time, since each frame is an integrated structure formed with the hollow main circular tube beam 1, its overall structural strength can be guaranteed, and the load-bearing performance of each frame structure can be effectively guaranteed. Its overall anti-deformation performance and load-bearing performance are significantly better than those of the traditional welded frame, and the effect of the entire tube beam assembly when installing the instrument panel components is better guaranteed.

[0090] In any of the above schemes, it is preferred that an overflow hole 13 connected to the internal central cavity 101 is provided on the outer wall of the horizontal straight pipe section 104 at the end of the central lock mounting base 2, the steering column fixing base 3, and the instrument central main base 4. When the interior of the central cavity 101 at the corresponding position is filled with high-temperature rubber fluid, continued pouring will cause the high-temperature rubber fluid to flow out of the overflow hole 13.

[0091] Since the internal pouring amount cannot be determined during the pouring of high-temperature rubber fluid, adding each overflow hole 13 can determine whether the internal central cavity 101 at the chassis position is filled by observing whether high-temperature rubber fluid flows out of the overflow hole 13, thereby ensuring the controllability of the pouring operation.

[0092] In any of the above schemes, it is preferred that both ends of the hollow main circular tube beam 1 are evenly cut along its circumference and completely provided with a plurality of end connection parts 14, and each end connection part 14 is bolted and fixed to the lateral mounting bracket 8 at the corresponding position and is fixed by welding at the abutment part.

[0093] The two ends of the entire hollow main circular tube beam 1 adopt four end connection parts 14 when connecting with the lateral mounting bracket 8. Each end connection part 14 is an integrated structure with the hollow main circular tube beam 1, thereby achieving the following effects: enhancing the structural strength of the entire end connection part 14; at the same time, the multiple divergently arranged end connection parts 14 can ensure that it can be evenly connected and fixed with the lateral mounting bracket 8 at multiple points, effectively increasing the connection points and enhancing the structural strength of the connection; in addition, welding and fixing at the tight-fitting parts of the connection can better enhance the strength of the connection, and improve the overall connection and fixation between the lateral mounting bracket 8 and the end of the hollow main circular tube beam 1, ensuring the overall bearing strength of the entire hollow main circular tube beam 1 and the lateral mounting brackets 8 at both ends after installation, and reducing the risk of breakage or detachment at the connection parts.

[0094] Specific processing process:

[0095] The present invention also provides a method for processing and manufacturing the above-mentioned commercial vehicle tube beam assembly, comprising the following steps:

[0096] According to the drawings, a straight tube blank of the hollow main circular tube beam 1 is manufactured by extrusion molding;

[0097] After the straight tube blank of the hollow main round tube beam 1 is extruded, the designated parts of the straight tube blank are bent as needed to form the corresponding central lock mounting base 2, the steering column fixing base 3, and the instrument center main base 4, so that the hollow main round tube beam 1 forms an integrated bent structure;

[0098] Four sections of the hollow main circular tube beam 1 are cut evenly along the circumference thereof, each section having a length of 50-100 mm. The four sections of the cut tube wall are bent outward in sequence to form end connection portions 14.

[0099] Each end connection portion 14 is an integrated structure with the hollow main circular tube beam 1, which can ensure the structural strength of each end connection portion 14, and at the same time increase the overall layout of the contact points and contact surfaces when the hollow main circular tube beam 1 is connected to the lateral mounting bracket 8, thereby ensuring the force balance of the connection part;

[0100] After the hollow main circular tube beam 1 is placed on a machining center and positioned using a tool, each mounting through hole 105 is machined at the bent portion where each coaxially arranged straight tube section 104 of the hollow main circular tube beam 1 is connected. During machining, each mounting through hole 105 is controlled to maintain the coaxiality accuracy requirement with the central cavity 101 of the hollow main circular tube beam 1, and after each mounting through hole 105 is machined, the surrounding burrs are ground off.

[0101] Effectively ensuring the coaxiality accuracy requirement can ensure the smoothness of the hollow auxiliary steel pipe 15 during the later insertion, and prevent the insertion from being blocked; at the same time, grinding the burrs around each installation through hole 105 after processing can effectively make its surface smooth, reducing the scratches and wear of each installation through hole 105 on the outer wall of the hollow auxiliary steel pipe 15;

[0102] Processing the reinforced crossbeam sub-parts, placing the hollow auxiliary steel pipe 15 on the CNC machine tool and clamping and positioning it, then processing each injection molding circulation long hole 9 in its designated position in sequence, and grinding the burrs of each injection molding circulation long hole 9;

[0103] Assemble the processed hollow auxiliary steel pipe 15 and the hollow main circular tube beam 1 to form a tube-beam assembly;

[0104] The pipe-beam assembly adopts a hollow structure composed of an external rigid structure and an internal rigid structure to improve the rigidity of the entire structure;

[0105] The resulting pipe-beam assembly is sent to a heat treatment process and high-temperature tempering is performed on the entire pipe-beam assembly and the weld area. The specific operation is as follows: the pipe-beam assembly is placed in a heat treatment furnace and heated to a temperature below Ac1 and then subjected to heat preservation treatment, so that plastic flow occurs in the pipe-beam assembly where the yield limit is reduced and the internal stress is high at high temperature. The elastic deformation gradually decreases, the plastic deformation gradually increases, and the stress is reduced. After the heat treatment, the pipe-beam assembly is removed and cooled;

[0106] Heat treatment of the pipe-beam assembly can effectively increase the toughness and plasticity of its structure and improve the mechanical properties of the pipe-beam assembly;

[0107] Injection molding of the elastic connection matrix 11 in the whole beam and the elastic support matrix 12 of the bottom frame is completed in the tube-beam assembly;

[0108] After injection molding, the elastic connection matrix 11 in the whole beam and the elastic support matrix 12 in the chassis can form a four-layer structure of rigid-flexible sandwiching of the entire tube-beam assembly with the internal rubber structure. From the inside to the outside, they are respectively the rigid layer of the hollow main circular tube beam 1, the elastic connection matrix 11 layer in the outer whole beam, the rigid layer in the hollow secondary steel pipe 15, and the elastic connection matrix 11 layer in the center part of the whole beam that passes through the cavity 10. The four-layer sandwich structure composed of rigid and flexible structures can effectively ensure the rigid strength of the entire structure. At the same time, the two layers of elastic connection matrix 11 in the whole beam can provide flexible elastic support for the rigid layer, thereby effectively ensuring the rigid support and flexible reset performance of the entire structure, effectively reducing the problem of deformation of the hollow main circular tube beam 1 caused by impact, and improving its self-reset ability.

[0109] Spraying an anti-corrosion coating on the outer surface of the pipe-beam assembly and completing the processing of the pipe-beam assembly after drying;

[0110] Install the central lock bracket 5, steering column bracket 6, and instrument center main bracket 7 on the corresponding central lock mounting base 2, steering column fixing base 3, and instrument center main base 4 in sequence;

[0111] Install the lateral mounting brackets 8 and related accessories at both ends;

[0112] Since the central locking mounting base 2, the steering column fixing base 3, and the instrument center main base 4 are an integrated structure, the base can be used as the main support and the brackets as auxiliary supports when installing the central locking bracket 5, the steering column bracket 6, and the instrument center main bracket 7 thereon. At the same time, each bracket can be temporarily or on-site installed according to installation requirements. At the same time, brackets of different sizes can be installed as needed, and the overall versatility is strong.

[0113] Check the connection strength of the assembly connection parts, and complete the assembly of the commercial vehicle tube beam assembly after passing the inspection;

[0114] Packing and shipping.

[0115] In any of the above solutions, preferably, the specific steps of completing the injection molding of the elastic connection matrix 11 in the entire beam and the elastic support matrix 12 of the chassis in the tube-beam assembly include:

[0116] Adjust the working position of the pipe-beam assembly, and then connect the ends of the cooled pipe-beam assembly to the external high-temperature injection molding pipeline; use high-pressure injection molding equipment to inject high-temperature rubber fluid from the ends of the hollow auxiliary steel pipe 15 of the pipe-beam assembly;

[0117] The high-temperature flowing rubber fluid is controlled to sequentially fill the through cavities 10 of the hollow secondary steel pipes 15, and then the high-temperature flowing rubber fluid is continuously injected so as to flow along each injection molding flow hole 9 into the corresponding central cavity 101 and complete the filling of each central cavity 101 at the corresponding position.

[0118] Control the filling flow rate and speed, and observe the filling status. When the central cavity 101 of each straight tube section 104 of the hollow main circular tube beam 1 is filled, the high-temperature flowing rubber fluid will overflow from both ends of the hollow main circular tube beam 1.

[0119] When the overflow holes 13 at the central lock mounting frame 2, the steering column fixing frame 3, and the instrument center main frame 4 flow out the high-temperature flowing rubber fluid, the hollow cavities at the corresponding positions are fully filled.

[0120] After the injection molding is completed and the rubber fluid inside the tube-beam assembly is cooled, an elastic connection matrix 11 inside the whole beam and an elastic support matrix 12 for the bottom frame are formed at the corresponding positions;

[0121] Cut off the excess rubber overflowing from the pipe-beam assembly.

[0122] When performing injection molding of high-temperature rubber fluid, the central through-hole 10 is firstly injected, and then the injection flow long holes 9 are coordinated to diverge and flow outward, filling the central cavity 101 of the straight pipe section 104 and the central cavity 101 of the chassis structure to realize the injection molding of the elastic connection matrix 11 in the whole beam and the elastic support matrix 12 of the chassis, effectively realizing the internal integral molding connection of the elastic connection matrix 11 in the whole beam and the elastic support matrix 12 of the chassis, and at the same time enhancing the structural strength of the entire rubber elastic structure, ensuring that after forming the four-layer structure of rigid-flexible sandwich, the four-layer sandwich structure consisting of the rigid layer of the hollow main circular tube beam 1, the elastic connection matrix 11 layer in the outer whole beam, the rigid layer in the hollow auxiliary steel pipe 15, and the elastic connection matrix 11 layer in the center of the through-hole 10 can effectively ensure the rigidity of the entire structure;

[0123] In any of the above solutions, preferably, the specific steps of assembling the hollow auxiliary steel pipe 15 and the hollow main circular tube beam 1 include:

[0124] The hollow main tube beam 1 is transferred to the assembly station and horizontally positioned using a tool. The hollow auxiliary steel pipe 15 that matches the hollow inner cavity of the hollow main tube beam 1 is inserted inward from one end of the hollow main tube beam 1. Before installation, the end of the hollow auxiliary steel pipe 15 is chamfered and polished to reduce the difficulty of assembly.

[0125] Chamfer grinding effectively forms the end guide part, effectively ensuring smoothness during insertion;

[0126] When the front end of the hollow auxiliary steel pipe 15 reaches each installation through hole 105, the insertion speed is controlled and the circumferential direction is continuously adjusted to control the hollow auxiliary steel pipe 15 to pass through each installation through hole 105 in sequence, and finally to move out from the other end of the hollow main circular tube beam 1;

[0127] Since each installation through hole 105 and the hollow main circular tube beam 1 are coaxial structures, the smoothness of installation can be effectively guaranteed during the installation of the hollow secondary steel tube 15 .

[0128] Rotate and adjust the hollow auxiliary steel pipe 15 so that each injection flow long hole 9 is aligned with the corresponding central cavity 101 and adjust it into place in the axial direction;

[0129] The purpose of axial adjustment is to achieve communication between each injection molding flow hole 9 and the central cavity 101 at the corresponding position;

[0130] After adjustment, the two ends of the hollow auxiliary steel pipe 15 are pre-fixed by spot welding at the contact parts of the corresponding ends of the hollow main circular tube beam 1 to prevent the relative displacement of the hollow auxiliary steel pipe 15 and the hollow main circular tube beam 1;

[0131] After spot welding pre-fixation, the relative positioning of the hollow auxiliary steel pipe 15 and the hollow main circular tube beam 1 can be effectively guaranteed, thereby achieving pre-positioning for the subsequent reinforcement welding;

[0132] The outer wall of the hollow secondary steel pipe 15 at each installation through hole 105 is welded to the corresponding side wall joint of the hollow main circular tube beam 1, and full welding is used during welding to prevent leakage at the joint;

[0133] At this point, the hollow secondary steel pipe 15 and the hollow main circular tube beam 1 are assembled.

[0134] The central lock mounting base 2, the steering column fixing base 3, and the instrument center main base 4 of the commercial vehicle tube beam assembly in the present invention are formed by integrally bending part of the structure of the hollow main circular tube beam 1, which can effectively ensure the integral forming of the entire frame body, and effectively improve the overall structural strength and anti-collision performance of the entire hollow main circular tube beam 1 structure when it is installed in conjunction with the commercial vehicle instrument; at the same time, considering the load resistance strength under the extreme load working load, a hollow auxiliary steel pipe 15 is also coaxially installed inside the hollow main circular tube beam 1 for reinforcing the structure of the hollow main circular tube beam 1 as a crossbeam pipe fitting, so that it forms a tube beam assembly, effectively ensuring the structural strength of the entire tube beam assembly.

[0135] The hollow structure of the tube-beam assembly composed of the hollow secondary steel pipe 15 and the hollow main circular tube beam 1 adopts high-temperature injection rubber to form the elastic connection matrix 11 inside the whole beam and the elastic support matrix 12 of the base frame, so that the entire tube-beam assembly forms a structural form that is soft inside and hard outside, so that its deformation resistance when it is hit is further enhanced. At the same time, due to the existence of the elastic connection matrix 11 inside the whole beam and the elastic support matrix 12 on the base frame, it can effectively prevent the hollow main circular tube beam 1 from deforming after being hit; improve the deformation self-recovery ability of the entire tube-beam assembly structure, and improve its deformation resistance and bending resistance; the elastic connection matrix 11 inside the whole beam and the elastic support matrix 12 on the base frame are integrally cast and molded, so after the elastic connection matrix 11 inside the whole beam and the elastic support matrix 12 on the base frame are formed, they form a whole inside the central cavity 101 and the through cavity 10, which can effectively prevent relative rotation between the hollow secondary steel pipe 15 and the hollow main circular tube beam 1, and ensure the internal stability of the entire tube-beam assembly structure. At the same time, since the elastic connection matrix 11 in the whole beam is filled and solidified in the central cavity 101 between the adjacent inner tube reinforcement sheet metal ribs 102, the elastic connection matrix 11 in the whole beam after forming can further realize the circumferential limitation of the hollow secondary steel pipe 15 and the hollow main circular tube beam 1, and effectively form a rigid and flexible overall structure of the hollow secondary steel pipe 15, the hollow main circular tube beam 1, the elastic connection matrix 11 in the whole beam, and the elastic support matrix 12 of each chassis, to ensure the load resistance of the entire tube beam assembly when it is hit. At the same time, due to the presence of the rubber material of the elastic connection matrix 11 in the whole beam and the elastic support matrix 12 of each chassis as a buffer, it can play a role in vibration reduction and noise reduction, effectively improving the NVH performance of the commercial vehicle.

[0136] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or make equivalent replacements for some or all of the technical features therein. These modifications or replacements do not deviate the essence of the corresponding technical solutions from the scope of the technical solutions of the embodiments of the present invention, and they should all be included in the scope of the claims and description of the present invention. For those skilled in the art, any replacement improvements or changes made to the implementation methods of the present invention fall within the scope of protection of the present invention.

[0137] Any matters not described in detail in the present invention are well-known technologies to those skilled in the art.

Claims

1. Commercial vehicle tube beam assembly, characterized by: It comprises a hollow main circular tube beam, on which a central locking mounting frame, a steering column fixing frame, and a central main instrument frame are integrally formed and bent in sequence from left to right, with the central locking mounting frame, the steering column fixing frame, and the central main instrument frame being located on different planes; A central lock bracket is detachably fixedly mounted on the central lock mounting base, and the central lock bracket is used to provide mounting support for the central lock of a commercial vehicle. A steering column bracket is detachably fixedly mounted on the steering column fixing base, and the steering column bracket is used to provide mounting support for the central lock of a commercial vehicle. An instrument central main bracket is detachably fixedly mounted on the instrument central main base, and the instrument central main bracket is used to provide mounting support for the central control unit of a commercial vehicle. Lateral mounting brackets are fixedly mounted on the left and right ends of the hollow main circular tube beam respectively; A plurality of inner tube reinforcing sheet metal ribs are integrally formed on the inner wall of the central cavity of the hollow main circular tube beam, and each inner tube reinforcing sheet metal rib is integrally formed with the hollow main circular tube beam; A strengthening crossbeam sub-component is respectively inserted into the central cavity of the coaxially arranged straight tube section of the hollow main circular tube beam, and the strengthening crossbeam sub-component is used to achieve structural reinforcement of each coaxially arranged straight tube section of the hollow main circular tube beam. The two ends of the strengthening crossbeam sub-component respectively pass through the preset mounting through holes at the outer ends of the corresponding bending parts of the hollow main circular tube beam and are respectively fixedly connected to the lateral mounting brackets at the corresponding positions; The reinforced crossbeam sub-component includes a horizontally arranged hollow auxiliary steel pipe, and a plurality of injection-molded flow long holes are respectively provided on the outer side walls of the hollow auxiliary steel pipe in each straight pipe section coaxially arranged in the hollow main circular tube beam. Each of the injection-molded flow long holes connects the through cavity of the hollow auxiliary steel pipe with the central cavity between the two inner tube reinforcement sheet metal ribs of the hollow main circular tube beam at the corresponding position, and the inner end of each inner tube reinforcement sheet metal rib is used to abut against the outer side wall of the hollow auxiliary steel pipe.

2. The commercial vehicle tubular beam assembly according to claim 1, characterized in that: Each bending portion of the hollow main circular tube beam is a rounded bend structure.

3. The commercial vehicle tubular beam assembly according to claim 2, characterized in that: The contact areas between the outer side walls of the reinforcing cross beam sub-components at each of the mounting through holes and the outer side walls of the hollow main circular tube beam are fully welded.

4. The commercial vehicle tubular beam assembly according to claim 3, characterized in that: High-temperature rubber fluid is injection-molded into the through-cavity of the hollow secondary steel pipe. After the rubber fluid fills the through-cavity, it flows out from each injection-molded flow hole into the central cavity between the hollow secondary steel pipe and the hollow main circular tube beam and fills the central cavity. After the high-temperature rubber fluid cools and solidifies, an elastic connection matrix is ​​formed in the entire beam. The elastic connection matrix in the entire beam is used to fill the hollow space between the hollow secondary steel pipe and the hollow main circular tube beam and enhance their structural strength and anti-deformation ability.

5. The commercial vehicle tubular beam assembly according to claim 4, characterized in that: Both ends of the hollow main circular tube beam are evenly cut along its circumference and are completely provided with a plurality of end connection parts, each of the end connection parts is bolted and fixed to the lateral mounting bracket at the corresponding position and is fixed by welding at the abutment position.

6. A method for manufacturing a commercial vehicle tubular beam assembly, wherein the commercial vehicle tubular beam assembly is the commercial vehicle tubular beam assembly as claimed in claim 5, characterized in that: The manufacturing method comprises the following steps: According to the drawings, straight tube blanks of hollow main round tube beams are manufactured by extrusion molding; After the straight tube blanks of the hollow main round tube beams are extruded, the designated parts of the straight tube blanks are bent as needed to form the corresponding central lock mounting frame, steering column fixing frame, and instrument center main frame, so that the hollow main round tube beams form an integrated bent structure; Four sections of 50-100 mm long are cut evenly along the circumference of each end of the hollow main circular tube beam, and the four sections of the cut tube wall are bent outward in sequence to form end connection parts; After the above-mentioned hollow main circular tube beam is placed on the machining center and positioned using the tooling, each mounting through hole is machined at the bending portion where each coaxially arranged straight tube section of the hollow main circular tube beam is connected. During machining, each mounting through hole is controlled to maintain the coaxiality accuracy requirement with the central cavity of the hollow main circular tube beam, and the surrounding burrs of each mounting through hole are polished after the machining is completed; Processing and strengthening the crossbeam sub-parts, after the hollow auxiliary steel pipe is placed on the CNC machine tool and clamped and positioned, each injection molding flow long hole is processed in its designated position in sequence, and the burrs of each injection molding flow long hole are polished; Assemble the processed hollow secondary steel pipe and the hollow main circular tube beam to form a tube-beam assembly; The resulting pipe-beam assembly is sent to a heat treatment process and high-temperature tempering is performed on the entire pipe-beam assembly and the weld area. The specific operation is as follows: the pipe-beam assembly is placed in a heat treatment furnace and heated to a temperature below Ac1 and then subjected to heat preservation treatment, so that plastic flow occurs in the pipe-beam assembly where the yield limit is reduced and the internal stress is high at high temperature. The elastic deformation gradually decreases, the plastic deformation gradually increases, and the stress is reduced. After the heat treatment, the pipe-beam assembly is removed and cooled; Injection molding of the elastic connection matrix in the whole beam and the elastic support matrix of the chassis are completed in the tube-beam assembly; Spraying an anti-corrosion coating on the outer surface of the pipe-beam assembly and completing the processing of the pipe-beam assembly after drying; Install the central lock bracket, steering column bracket, and instrument center main bracket on the corresponding central lock mounting bracket, steering column fixing bracket, and instrument center main bracket in sequence; Install the lateral mounting brackets and related accessories at both ends; Check the connection strength of the assembly connection parts, and complete the assembly of the commercial vehicle tube beam assembly after passing the inspection; Packing and shipping.

7. The method for manufacturing a commercial vehicle tube beam assembly according to claim 6, characterized in that: The specific steps of completing the injection molding of the elastic connection matrix in the entire beam and the elastic support matrix of the base frame in the tube-beam assembly include: Adjust the working position of the pipe-beam assembly, and then connect the ends of the cooled pipe-beam assembly to the external high-temperature injection molding pipeline; use high-pressure injection molding equipment to inject high-temperature rubber fluid from the ends of the hollow secondary steel pipes of the pipe-beam assembly; The high-temperature flowing rubber fluid is controlled to fill the through cavities of the hollow secondary steel pipes in turn, and then the high-temperature flowing rubber fluid is continued to flow along each injection flow hole into the corresponding central cavity and complete the complete filling of each central cavity of the corresponding part; Control the filling flow rate and speed, and observe the filling status. When the central cavity of each straight tube section of the hollow main circular tube beam is filled, the high-temperature flowing rubber fluid will overflow from both ends of the hollow main circular tube beam; When the overflow holes of the central locking mounting frame, the steering column mounting frame, and the instrument panel center main frame are filled with high-temperature rubber fluid, the hollow cavities at the corresponding positions are fully filled. After the injection molding is completed and the rubber fluid inside the tube-beam assembly is cooled, an elastic connection matrix inside the whole beam and an elastic support matrix of the chassis are formed at the corresponding positions; Cut off the excess rubber overflowing from the pipe-beam assembly.

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