A multi-material lightweight cage cab skeleton structure

Abstract

The present application relates to a kind of multi-material lightweight cage cab skeleton structure, including vehicle upper assembly and vehicle lower assembly, vehicle upper assembly is fixedly connected with vehicle lower assembly;Vehicle lower assembly includes front wall assembly, floor assembly, rear wall assembly;Floor assembly is integrated structure;Front wall assembly and rear wall assembly are respectively arranged in the front end and rear end of floor assembly;Vehicle upper assembly is fixedly connected with vehicle lower assembly by front wall assembly and rear wall assembly.Cab body skeleton structure is formed by connecting vehicle upper assembly and vehicle lower assembly, which simplifies the vehicle body skeleton structure and connection mode;At the same time, vehicle upper assembly and vehicle lower assembly are both aluminum profiles with reinforcing ribs inside, which reduces the overall weight of the vehicle body skeleton while ensuring overall rigidity and strength, and makes the vehicle body skeleton have sufficient strength and torsional strength, avoiding the driver injury caused by the deformation of cab.

Description

Technical Field

[0001] This invention relates to the field of automotive structural technology, and in particular to a multi-material lightweight cage-shaped cab frame structure. Background Technology

[0002] The cab is a crucial component of commercial vehicles, serving as the driver's workspace. Its structure directly impacts driver safety, work efficiency, and health. Existing cab frame structures typically utilize welded thin metal sheets and do not bear loads. Therefore, in the event of a collision or rollover, the vehicle experiences tremendous impact forces. The existing cab frame structure lacks sufficient rigidity and torsional strength, leading to cab deformation and driver injury. Furthermore, existing cab frames are heavy, have numerous parts, and involve complex structures and connection processes. Summary of the Invention

[0003] This invention proposes a multi-material lightweight cage-shaped cab frame structure. By connecting the upper body assembly and the lower body assembly to form a cage-like body frame structure, the body frame structure and connection method are simplified. At the same time, both the upper body assembly and the lower body assembly are made of aluminum profiles, which reduces the overall weight of the body frame while ensuring overall rigidity and strength, and gives the body frame sufficient strength and torsional strength to avoid driver injury when the cab is deformed.

[0004] To address the problems mentioned above in the background section, the present invention is achieved through the following technical solution:

[0005] A multi-material lightweight cage-shaped cab frame structure includes an upper body assembly and a lower body assembly, wherein the upper body assembly and the lower body assembly are fixedly connected; the lower body assembly includes a front bulkhead assembly, a floor assembly, and a rear bulkhead assembly; the floor assembly is an integral structure; the front bulkhead assembly and the rear bulkhead assembly are respectively located at the front end and rear end of the floor assembly; the upper body assembly is fixedly connected to the lower body assembly through the front bulkhead assembly and the rear bulkhead assembly.

[0006] Preferably, the front bulkhead assembly includes an upper front baffle assembly and a lower front baffle assembly, the upper front baffle assembly and the lower front baffle assembly being fixedly connected by welding; the lower front baffle assembly and the front end of the floor assembly are fixedly connected by SPR self-piercing rivets and structural adhesive; the rear bulkhead assembly includes a rear bulkhead outer panel and a rear bulkhead crossbeam; the rear bulkhead crossbeam includes a rear bulkhead upper crossbeam and a rear bulkhead lower crossbeam; the rear bulkhead outer panel is disposed between the rear bulkhead upper crossbeam and the rear bulkhead lower crossbeam, and is located at the... The rear upper crossbeam and the outer end of the rear lower crossbeam; the inner end of the rear upper crossbeam is connected to the upper body assembly; the inner end of the rear lower crossbeam is connected to the floor assembly; the front assembly, the floor assembly, and the rear crossbeam are all aluminum profiles with internal reinforcing ribs, and the rear outer panel is an aluminum sheet stamping part; the left and right sides of the floor assembly are respectively provided with sill beams, and the sill beams are aluminum profiles with internal reinforcing ribs; the sill beams are connected to the floor assembly by FDS flow drill screws or bolts.

[0007] Preferably, the upper body assembly includes a roof assembly, a left side panel assembly, and a right side panel assembly; the upper ends of the left side panel assembly and the right side panel assembly are connected to the roof assembly; the lower ends of the left side panel assembly and the right side panel assembly are respectively connected to the floor assembly and the front panel assembly.

[0008] Preferably, both the left and right side enclosure assemblies are composed of an A-pillar assembly, a top edge beam assembly, a B-pillar assembly, and a sill beam assembly; the top edge beam assembly is connected to the sill beam assembly via the A-pillar assembly and the B-pillar assembly, respectively; the top edge beam assembly, B-pillar assembly, A-pillar assembly, and sill beam assembly are all aluminum profiles with internal reinforcing ribs; the A-pillar assembly also has a high-strength plate, which is connected to the A-pillar assembly by welding; the upper end of the A-pillar assembly is connected via an FDS flow... A drill screw or SPR self-piercing rivet is connected to one end of the connecting joint, and the other end of the connecting joint is connected to the top edge beam assembly via an FDS flow drill screw or SPR self-piercing rivet; the lower end of the A-pillar assembly is connected to the sill beam assembly via an FDS flow drill screw or SPR self-piercing rivet; the upper end of the B-pillar assembly is connected to the top edge beam assembly via an FDS flow drill screw or SPR self-piercing rivet; the lower end of the B-pillar assembly is connected to the sill beam assembly via an FDS flow drill screw or SPR self-piercing rivet.

[0009] Preferably, the top cover assembly includes a top cover outer plate, and the top cover outer plate is provided with a top cover crossbeam; the top cover assembly is connected to the left side panel assembly and the right side panel assembly through the top cover outer plate; the top cover crossbeam is an aluminum profile with internal reinforcing ribs, and the top cover outer plate is an aluminum plate stamping part.

[0010] Compared with the prior art, the present invention has the following beneficial technical effects:

[0011] 1. By connecting the upper body assembly and the lower body assembly to form a cage-like body frame structure, the body frame structure and connection method are simplified; at the same time, both the upper body assembly and the lower body assembly are made of aluminum profiles with internal reinforcing ribs, which reduces the overall weight of the body frame while ensuring overall rigidity and strength, and gives the body frame sufficient strength and torsional strength to avoid driver injury when the cab is deformed.

[0012] 2. The A-pillar assembly is equipped with a high-strength plate, which helps to improve the side collision safety performance of the whole vehicle. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the exploded structure of the present invention;

[0014] Figure 2 This is a schematic diagram of the structure of the present invention;

[0015] Figure 3 for Figure 2 Sectional view at point AA;

[0016] Figure 4 This is a schematic diagram of the B-pillar assembly structure of the present invention;

[0017] Figure 5 for Figure 4 Sectional view at point BB;

[0018] Figure 6 This is a schematic diagram of the sill beam assembly structure of the present invention;

[0019] Figure 7 for Figure 6 Sectional view at CC;

[0020] Figure 8 This is a schematic diagram of the floor assembly structure of the present invention;

[0021] Figure 9 This is a schematic diagram of the top cover assembly structure of the present invention;

[0022] Figure 10 This is an assembly state diagram of the present invention.

[0023] Explanation of reference numerals in the attached figures

[0024] 10. Front bulkhead assembly; 11. Upper front fender assembly; 12. Lower front fender assembly; 20. Floor assembly; 30. Rear bulkhead assembly; 31. Rear bulkhead outer panel; 40. Roof assembly; 41. Left side bulkhead assembly; 42. Right side bulkhead assembly; 43. A-pillar assembly; 44. Top edge beam assembly; 45. B-pillar assembly; 46. Sill beam assembly. Detailed Implementation

[0025] like Figures 1-6 As shown, a multi-material lightweight cage-like cab frame structure includes an upper body assembly and a lower body assembly, which are fixedly connected. The lower body assembly includes a front bulkhead assembly 10, a floor assembly 20, and a rear bulkhead assembly 30. The floor assembly 20 is a one-piece structure. The front bulkhead assembly 10 and the rear bulkhead assembly 30 are respectively located at the front and rear ends of the floor assembly 20. The upper body assembly is fixedly connected to the floor assembly 20 through the front bulkhead assembly 10 and the rear bulkhead assembly 30. The connection between the upper body assembly and the lower body assembly forms a cage-like body frame structure, simplifying the body frame structure and connection method. Simultaneously, the front bulkhead assembly 10, the floor assembly 20, and the rear bulkhead assembly 30 are all made of aluminum profiles, which reduces the overall weight of the body frame while ensuring overall rigidity and strength, and provides sufficient strength and torsional strength to prevent driver injury when the cab is deformed.

[0026] The front bulkhead assembly 10 includes an upper front bulkhead assembly 11 and a lower front bulkhead assembly 12, which are fixedly connected by welding. The lower front bulkhead assembly 12 is fixedly connected to the front end of the floor assembly 20 by SPR self-piercing rivets and structural adhesive. The rear bulkhead assembly 30 includes a rear outer panel 31 and a rear crossbeam. The rear crossbeam includes an upper rear crossbeam and a lower rear crossbeam. The rear outer panel 31 is located between the upper and lower rear crossbeams. The rear upper crossbeam and the rear lower crossbeam are located at their outer ends; the inner end of the rear upper crossbeam is connected to the upper body assembly; the inner end of the rear lower crossbeam is connected to the floor assembly 20; the front assembly 10, the floor assembly 20, and the rear crossbeam are all aluminum profiles with internal reinforcing ribs, and the rear outer panel 31 is an aluminum sheet stamping; the left and right sides of the floor assembly 20 are respectively provided with sill beams, and the sill beams are aluminum profiles with internal reinforcing ribs; the sill beams are connected to the floor assembly 20 by FDS flow drill screws or bolts. The front assembly 10, the floor assembly 20, and the rear assembly 30 are all made of aluminum profiles, which reduces the overall weight of the body frame while ensuring overall rigidity and strength, and gives the body frame sufficient strength and torsional strength. The rear outer panel 31 is sealed, and the use of aluminum sheet stamping for the rear outer panel 31 reduces mold development while achieving the lightweighting and integration of the whole vehicle.

[0027] Self-piercing riveting (SPR) is an existing technology and a cold joining method that uses rivets to penetrate and connect two or more layers of different materials. SPR can join a variety of materials, including high-strength steel, galvanized steel, aluminum, plastics, and composite materials. It can join different materials together and can even join materials with various surface coatings without affecting the connection, such as lubricated, painted, coated, or electroplated materials. SPR can also be used to join materials that incorporate sealants, adhesives, or insulation materials.

[0028] Flow Drill Screw (FDS) is an existing technology that uses hot-melt rotary tapping and riveting. Its principle is to use the heat generated by the high-speed rotation of the screw to melt the base material, increasing pressure to penetrate the base material and create threads, thus fixing two or more layers of sheet metal together. FDS can be used to join dissimilar or homogeneous metals. It is currently widely used in aluminum car bodies.

[0029] The upper body assembly includes a roof assembly 40, a left side panel assembly 41, and a right side panel assembly 42; the upper ends of the left side panel assembly 41 and the right side panel assembly 42 are connected to the roof assembly 40; the lower ends of the left side panel assembly 41 and the right side panel assembly 42 are connected to the floor assembly 20 and the front panel assembly 10, respectively.

[0030] Both the left side assemblies 41 and 42 are composed of A-pillar assemblies 43, top edge beam assemblies 44, B-pillar assemblies 45, and sill beam assemblies 46. The top edge beam assembly 44 is connected to the sill beam assembly 46 via the A-pillar assemblies 43 and B-pillar assemblies 45. The top edge beam assembly 44, B-pillar assemblies 45, A-pillar assemblies 43, and sill beam assemblies 46 are all aluminum profiles with internal reinforcing ribs. The A-pillar assembly 43 also has a high-strength plate, which is connected to the A-pillar assembly 43 by welding. The upper end of the A-pillar assembly 43 is connected via F... DS-type flow screws or SPR self-piercing rivets connect to one end of the connecting joint, and the other end of the connecting joint connects to the top side beam assembly 44 via FDS-type flow screws or SPR self-piercing rivets. The lower end of the A-pillar assembly 43 connects to the sill beam assembly 46 via FDS-type flow screws or SPR self-piercing rivets. The upper end of the B-pillar assembly 45 connects to the top side beam assembly 44 via FDS-type flow screws or SPR self-piercing rivets; the lower end of the B-pillar assembly 45 connects to the sill beam assembly 46 via FDS-type flow screws or SPR self-piercing rivets. The A-pillar assembly 43 is made of high-strength steel, which helps improve the side collision safety performance of the entire vehicle. At the same time, the top side beam assembly 44, B-pillar assembly 45, and sill beam assembly 46 are all made of aluminum profiles with internal reinforcing ribs, resulting in a lightweight and high-strength overall vehicle body frame with superior collision safety performance. This contributes to the lightweighting of electric commercial vehicles and can effectively extend the driving range of electric vehicles.

[0031] The roof assembly 40 includes an outer roof panel with a roof crossbeam. The roof assembly 40 is connected to the left side panel assembly 41 and the right side panel assembly 42 via the outer roof panel. The roof crossbeam is an aluminum profile with internal reinforcing ribs, and the outer roof panel is an aluminum sheet stamping. The outer roof panel provides sealing, and the use of aluminum sheet stamping reduces mold development while achieving lightweighting and integration of the entire vehicle.

Claims

1. A multi-material lightweight cab cage structure, characterized by: The body upper assembly and the body lower assembly are fixedly connected; the body lower assembly includes a front wall assembly (10), a floor assembly (20), and a rear wall assembly (30); the floor assembly (20) is of an integrated structure; the front wall assembly (10) and the rear wall assembly (30) are respectively arranged at the front end and the rear end of the floor assembly (20); the body upper assembly is fixedly connected with the floor assembly (20) through the front wall assembly (10) and the rear wall assembly (30); The front wall assembly (10) includes a front apron upper assembly (11) and a front apron lower assembly (12), and the front apron upper assembly (11) and the front apron lower assembly (12) are fixedly connected through welding; the front apron lower assembly (12) is fixedly connected with the front end of the floor assembly (20) through SPR self-punch riveting and structural adhesive bonding; the rear wall assembly (30) includes a rear wall outer plate (31) and a rear wall cross beam; the rear wall cross beam includes a rear wall upper cross beam and a rear wall lower cross beam; the rear wall outer plate (31) is arranged between the rear wall upper cross beam and the rear wall lower cross beam and located at the outer ends of the rear wall upper cross beam and the rear wall lower cross beam; the inner end of the rear wall upper cross beam is connected with the body upper assembly; the inner end of the rear wall lower cross beam is connected with the floor assembly (20); the front wall assembly (10), the floor assembly (20), and the rear wall cross beam are all aluminum profiles with reinforcing ribs inside; the rear wall outer plate (31) is an aluminum plate stamping part; the left and right sides of the floor assembly (20) are respectively arranged at rocker beams, and the rocker beams are aluminum profiles with reinforcing ribs inside; the rocker beams are connected with the floor assembly (20) through FDS flow-drilling screws or bolts; The body upper assembly includes a roof assembly (40), a left side wall assembly (41), and a right side wall assembly (42); the upper ends of the left side wall assembly (41) and the right side wall assembly (42) are connected with the roof assembly (40); the lower ends of the left side wall assembly (41) and the right side wall assembly (42) are respectively connected with the floor assembly (20) and the front wall assembly (10); The left side wall assembly (41) and the right side wall assembly (42) are each composed of an A-pillar assembly (43), a roof rail assembly (44), a B-pillar assembly (45) and a rocker beam assembly (46); the roof rail assembly (44) is connected with the rocker beam assembly (46) through the A-pillar assembly (43) and the B-pillar assembly (45) respectively; the roof rail assembly (44), the B-pillar assembly (45), the A-pillar assembly (43) and the rocker beam assembly (46) are all aluminum profiles with reinforcing ribs inside; the A-pillar assembly (43) is further provided with a high-strength plate, which is connected with the A-pillar assembly (43) by welding; the upper end of the A-pillar assembly (43) is connected with one end of a connecting joint through FDS flow-drilling screws or SPR self-piercing rivets, and the other end of the connecting joint is connected with the roof rail assembly (44) through FDS flow-drilling screws or SPR self-piercing rivets; the lower end of the A-pillar assembly (43) is connected with the rocker beam assembly (46) through FDS flow-drilling screws or SPR self-piercing rivets; the upper end of the B-pillar assembly (45) is connected with the roof rail assembly (44) through FDS flow-drilling screws or SPR self-piercing rivets; the lower end of the B-pillar assembly (45) is connected with the rocker beam assembly (46) through FDS flow-drilling screws or SPR self-piercing rivets. The roof assembly (40) comprises a roof outer plate, and the roof outer plate is provided with a roof cross beam; the roof assembly (40) is connected with the left side wall assembly (41) and the right side wall assembly (42) through the roof outer plate; the roof cross beam is an aluminum profile with reinforcing ribs inside, and the roof outer plate is an aluminum plate stamping part.

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