A torsion box and a floor beam structure having a torsion box

Abstract

The application discloses a torsion box and a floor beam structure with the same, which comprises a tubular body with a porous structure made of aluminum alloy and a T-shaped threaded sleeve; the circumferential side wall of the tubular body with the porous structure is a plane, and the left and right ports of the tubular body with the porous structure are irregular notches composed of multiple continuous bevels; the T-shaped threaded sleeve is vertically arranged between the upper and lower end faces of the tubular body with the porous structure, and the upper end of the T-shaped threaded sleeve is exposed outside the upper end face of the tubular body with the porous structure; the application utilizes the variable characteristics of the cross section of the aluminum extruded profile in the torsion box and the floor, uses the aluminum alloy extruded structure with the same cross section, realizes the irregular torsion box structure, greatly simplifies the torsion box structure, reduces the number of parts of the torsion box and the floor beam structure, guarantees the high structural performance, greatly reduces the process investment and the part cost, and can be used in the front and rear floor beam systems and can be expanded to the beam system structure of a larger range of the floor.

Description

Technical Field

[0001] This invention relates to the field of automotive technology, and more particularly to a torsion box and a floor beam structure having a torsion box. Background Technology

[0002] As a key component of the automotive floor beam system, the torsion box structure is crucial to the overall stiffness and force transmission path of the floor.

[0003] The existing torsion box structures mainly include the following types:

[0004] First, the assembly formed by connecting thin sheet metal stamping parts has limited rigidity and strength. Multiple reinforcing plates can be added inside the torsion box to improve performance to some extent, making it the most common and mature traditional structure. However, its disadvantages include a large number of parts, numerous connection points, and complex manufacturing processes. Second, the cast aluminum torsion box structure avoids the disadvantages of the first approach, such as a large number of parts and connection points, and can provide good rigidity and strength through structural optimization. However, its disadvantages include a significant increase in process investment and part costs. The torsion box structure is irregular in three dimensions, requiring at least two molds for production, with mold costs around ten million yuan. Furthermore, it requires cold connection processes such as SPR (Self-Piercing Rivet, a cold forming process that creates a strong interlock between the rivet and the sheet metal) and FDS (Flow Drill Screw, a cold forming process that uses high-speed rotation of screws to heat-deform the sheet metal before tapping and riveting) to connect with surrounding parts, thus increasing the difficulty and investment of the floor assembly's connection process.

[0005] The corresponding floor beam system also has the same shortcomings as the first and second technical solutions mentioned in the description of the torsion box structure. Summary of the Invention

[0006] To address the aforementioned issues, this invention proposes a torsion box and a floor beam structure incorporating the torsion box. The variability of the aluminum extrusion profile cross-section is applied to the torsion box and floor. By designing a complex, irregularly shaped extrusion cross-section and using an aluminum alloy extrusion structure with a uniform cross-section, an irregular torsion box structure is achieved, significantly simplifying the torsion box structure. The entire floor beam system is designed using the same approach. Based on the aluminum alloy extrusion forming process, the torsion box structure and floor beam system reduce the number of parts required for the torsion box and floor beam structure while maintaining high structural performance. This also significantly reduces process investment and component costs (the mold cost for extrusion forming is only around one million yuan, far lower than the tens of millions of yuan cost for stamping and die-casting molds; component costs are slightly higher than stamping structures but significantly lower than aluminum die-casting structures). Furthermore, it allows for thermal connection with similar surrounding materials via seam welding, greatly shortening the product development and iteration cycle. This fundamentally solves the pain points of existing sheet metal stamping and welding solutions and aluminum die-casting solutions, and integrates the advantages of existing solutions to form a completely new design.

[0007] This invention proposes a torsion box, comprising a porous tubular body made of aluminum alloy and a T-shaped threaded sleeve. The porous structure of the tubular body plays a role in improving the overall torsional stiffness performance of the torsion box.

[0008] The porous tubular structure has planar circumferential sidewalls, and its left and right ends are irregular cuts composed of multiple continuous oblique cuts. These irregular cuts can be designed to avoid the chassis layout space in the corresponding position of the vehicle, resulting in a lighter part structure while simultaneously achieving three-dimensional force transmission. Existing sheet metal stamping and aluminum die-casting structures for torsion boxes have irregular shapes in three dimensions, while the blanks formed by aluminum profile extrusion can only grow linearly, generally only suitable for beam structures. To achieve three-dimensional structural construction and force transmission for the torsion box, this invention creatively decomposes the complex three-dimensional structure into two two-dimensional design features along the ZX plane and along the XY plane, thereby simplifying the structure and process. The design feature along the ZX plane, i.e., the extruded cross-sectional shape, is as follows... Figure 2As shown, breaking through the general regular cross-sectional shape, matching the surrounding design constraints and structural connection requirements, a structural connection requirement is constructed with an external matching space and an internal hollow, lightweight, yet highly rigid cross-sectional structure. The XY plane design features, namely the cutting boundaries on both sides of the torsion box, are two two-dimensional design features that enable the design scheme to meet the basic conditions of aluminum profile extrusion. Then, the two-dimensional features are creatively fitted in space to form a three-dimensional torsion box structure. By creatively cutting the two ends of the blank formed by the aluminum profile extrusion process irregularly, the force of the torsion box can be matched and connected in three dimensions and the force can be transmitted. Using an aluminum alloy extrusion structure with a constant cross-section, a three-dimensional irregular torsion box structure is realized, which greatly simplifies the torsion box structure. It can reduce the number of torsion box structural parts while ensuring high structural performance, and can also significantly reduce process investment and part costs. Furthermore, it can be thermally and coldly connected with similar surrounding materials through seam welding, which greatly shortens the product development and iteration cycle. It fundamentally solves the pain points of existing sheet metal stamping and welding solutions and aluminum die casting solutions, and integrates the advantages of existing solutions.

[0009] The T-shaped threaded sleeve is vertically inserted and fixed between the upper and lower end faces of the porous tubular body, with the upper end of the T-shaped threaded sleeve protruding outside the upper end face of the porous tubular body. The T-shaped threaded sleeve forms a fixing point for the subframe, battery, and other floor substructures.

[0010] The porous tubular structure is formed and cut using an aluminum profile extrusion process. The scraps cut from the aluminum profile extrusion process can be recycled, reducing production costs.

[0011] The porous tubular structure has a first rectangular tube, a second rectangular tube, and a third rectangular tube arranged vertically on its right side. To the left of these three tubes, there is an upper fourth rectangular tube and a lower right-angled triangular tube. A cantilevered structure extends outward from the upper left end of the right-angled triangular tube. This cantilevered structure is designed to connect with the beam assembly. The lower right side of the second rectangular tube and the right side of the third rectangular tube are integrally connected to a section that would otherwise be missing from the beam assembly. The missing connection in the crossbeam assembly is designed to allow for overlap with the measuring assembly and to facilitate the distribution of forces transmitted from the beam assembly to the torsion box to the crossbeam assembly. The upper surface of the fourth rectangular tube is higher than that of the first rectangular tube, and the upper right corner of the fourth rectangular tube has a right-sloping ramp. The lower end of the ramp connects to the left side of the upper surface of the first rectangular tube. The design of the ramp of the fourth rectangular tube and the upper surface of the first rectangular tube facilitates fixation to the subframe, battery, and other floor substructures. The porous tubular structure facilitates aluminum alloy extrusion. The equipment extrudes the blank, and the porous tubular structure has high rigidity and strength. The two ends of the extruded blank can be cut into irregular port shapes according to design requirements, which is beneficial for the three-dimensional dispersion and transmission of force, and also makes the torsion box lightweight. The cut scraps can be recycled, reducing production costs. The torsion box produced and cut by aluminum alloy extrusion molding process will disperse the force received by the beam assembly after being subjected to external force at the beam assembly through the crossbeam assembly, subframe, battery assembly, etc. connected to it. The first rectangular tube, the first The second and third rectangular tubes have corresponding perforations. The T-shaped threaded sleeve includes a circular base and a hollow tube fixedly connected to the circular base. The inner wall of the hollow tube has internal threads. The hollow tube passes through the perforations on the first, second, and third rectangular tubes respectively. The upper end of the hollow tube is exposed outside the upper end face of the first rectangular tube, and the circular base contacts and is welded to the lower end face of the third rectangular tube. The upper end of the T-shaped threaded sleeve forms a fixing point for the subframe, battery, and other floor substructures.

[0012] The tubular body with porous structure is respectively encapsulated with a left port sealing plate and a right port sealing plate at its left and right ends. The left port sealing plate and the right port sealing plate extend upwards from the left and right ends of the cantilever structure tube body, respectively, to form a positioning groove for the beam frame assembly connecting arm that overlaps and is fixed to the upper end face of the cantilever structure tube body. This restricts the left and right displacement of the beam frame assembly that overlaps and is fixed to the upper end face of the cantilever structure tube body, thereby reducing assembly deviation.

[0013] The lower rear ends of the left and right limit baffles are respectively bent outwards at the missing connection points of the crossbeam assembly to form left and right limit connecting baffles, so that the limit connecting baffles can make limit contact with the crossbeam assembly and be welded and fixed.

[0014] The present invention also proposes a floor beam structure with torsion boxes, including a crossbeam assembly, two torsion boxes and a beam frame assembly; the rear ends of the two torsion boxes are respectively welded and fixed to the crossbeam assembly, and the rear ends of the beam frame assembly are respectively welded and fixed to the front ends of the two torsion boxes.

[0015] The crossbeam assembly includes a honeycomb structure tube made of aluminum alloy. The circumferential sidewalls of the honeycomb structure tube are flat, and the cross-section of the honeycomb structure tube is L-shaped. The long arms of the L-shaped honeycomb structure tube include a first rectangular tube, a second rectangular tube, a third rectangular tube, and a long right-angled trapezoidal tube. The short arms of the L-shaped honeycomb structure tube include a first square tube, a second square tube, and a short right-angled trapezoidal tube. The first rectangular tube, the second rectangular tube, and the first square tube are arranged from top to bottom in a specific order. In this arrangement, the third rectangular tube and the long right-angled trapezoidal tube of the crossbeam are arranged vertically and positioned to the right of the first and second rectangular tubes of the crossbeam. The lower slope of the long right-angled trapezoidal tube matches and connects with the slope of the short right-angled trapezoidal tube of the crossbeam. The short right-angled trapezoidal tube and the second square tube of the crossbeam are arranged vertically and positioned to the right of the first square tube of the crossbeam. The right side of the third rectangular tube, the right side of the long right-angled trapezoidal tube, and the upper surface of the short right-angled trapezoidal tube together constitute the missing connection part of the crossbeam. The design is intended to connect the floor sill beam, avoiding the T-shaped connection between the sill beam and the crossbeam within a plane, which would result in a planar connection (forming a typical cantilever structure mechanical model, where the maximum torque is concentrated at the connection, increasing the strength requirements of the connection and necessitating more structural or higher-performance materials to support it). Instead, the connection is made spatially staggered, structurally reducing the probability of stress concentration at the connection, increasing the stiffness and strength of the connection, thereby improving the overall rigidity and strength of the vehicle body. The two ends of the honeycomb structure tube have symmetrical oblique cuts from the upper end face of the short right-angled trapezoidal tube of the crossbeam downwards. The front and rear side walls of the honeycomb structure tube have trapezoidal crossbeam notches cut from the bottom upwards. These crossbeam notches are for avoidance design and also make the crossbeam assembly lighter. The crossbeam assembly of the porous tubular body of each torsion box is missing a connecting part and is welded and fixed to the upper end face and front side of the corresponding crossbeam assembly. The left and right limiting connecting edges of each torsion box are respectively connected and welded to the front side limiting contact of the crossbeam assembly.

[0016] The honeycomb structure tubes are formed and cut from aluminum profiles using an extrusion process.

[0017] The beam frame assembly includes a left longitudinal beam, a right longitudinal beam, a left spring support, a right spring support, a bumper beam, a left support beam of the bumper beam, a right support beam of the bumper beam, a first cross beam and a second cross beam; the bumper beam is of a structure with a straight middle part and horizontally curved ends at both sides. The bumper beam has a larger transverse dimension, and large arc structures are adopted on both sides, and it is welded to the left and right support beams to form a collision guiding structure. When dealing with a small offset collision, it can better guide the oncoming vehicle and collision energy to the outside of the vehicle through the arc structure, thereby reducing the collision energy borne by itself, and thus reducing the weight and cost brought by the reinforcement structure. The front ends of the left longitudinal beam and the right longitudinal beam are respectively welded and fixed at the inner arc bending parts of the corresponding bumper beam. The anti-collision cross beam is directly welded to the longitudinal beam, eliminating the separate buffer energy absorption box, and directly absorbing energy through the deformation of the longitudinal beam, simplifying the structure. The first cross beam and the second cross beam are respectively welded and fixed between the left longitudinal beam and the right longitudinal beam, and the second cross beam is fixed at the rear ends of the corresponding side walls of the left longitudinal beam and the right longitudinal beam. The left spring support and the right spring support are respectively symmetrically welded and fixed on the lower end surfaces of the left longitudinal beam and the right longitudinal beam. One ends of the left support beam of the bumper beam and the right support beam of the bumper beam are respectively welded and fixed at the left end and the right end of the bumper beam, and the other ends of the left support beam of the bumper beam and the right support beam of the bumper beam are respectively welded and fixed on the outer side walls of the left longitudinal beam and the right longitudinal beam. The rear ends of the left longitudinal beam and the right longitudinal beam are respectively seated on the upper end surfaces of the cantilever structure tubes of the corresponding torsion boxes and welded and fixed, and the side walls of the left longitudinal beam and the right longitudinal beam are respectively in contact with and welded and fixed to the left limit flanges and the right limit flanges of each torsion box.

[0018] The left longitudinal beam, the right longitudinal beam, the bumper beam, the left support beam of the bumper beam, the right support beam of the bumper beam, the first cross beam and the second cross beam are all formed by aluminum profile extrusion process, and their cross-sections are all in the shape of "mouth", "day", "field" or "eye" to enhance their rigidity.

[0019] The left spring support and the right spring support are die-castings or sheet metal stamping parts.

[0020] Beneficial effects

[0021] This invention applies the variability of aluminum extrusion profile cross-sections to torsion boxes and flooring. By designing complex irregular extrusion cross-sections and using aluminum alloy extrusion structures with uniform cross-sections, an irregular torsion box structure is achieved, greatly simplifying the torsion box structure. The entire floor beam system structure is designed using the same approach. The torsion box structure and floor beam system structure made based on aluminum alloy extrusion forming process can reduce the number of parts in the torsion box and floor beam structure while ensuring high structural performance. It can also significantly reduce process investment and part costs (the mold cost for extrusion forming is only about one million yuan, far lower than the tens of millions of yuan cost for stamping and die-casting molds; the part cost is slightly higher than that of stamping structures, but significantly lower than that of aluminum die-casting structures). Furthermore, it can be thermally connected to similar surrounding materials through seam welding, greatly shortening the product development and iteration cycle. It fundamentally solves the pain points of existing sheet metal stamping and welding solutions and aluminum die-casting solutions, and integrates the advantages of existing solutions to form a completely new design solution. This solution can be used for the front floor beam system, the rear floor beam system, and can also be extended to a wider range of floor beam structures. Attached Figure Description

[0022] Figure 1 This is an exploded structural diagram of the torsion box of the present invention.

[0023] Figure 2 This is a schematic diagram of the cross-sectional structure of the torsion box of the present invention.

[0024] Figure 3 This is a schematic diagram of the extruded blank structure of the torque box of the present invention.

[0025] Figure 4 This is a three-dimensional structural diagram of the floor beam of the present invention.

[0026] Figure 5 This is an exploded structural diagram of the floor beam of the present invention.

[0027] Figure 6 This is a structural schematic diagram of the beam frame assembly of the present invention.

[0028] Figure 7 This is an exploded structural diagram of the beam assembly of the present invention.

[0029] Figure 8 This is a schematic diagram of the cross-sectional structure of the beam assembly of the present invention.

[0030] Figure 9 This is a three-dimensional structural diagram of the back side of the extruded preform of the crossbeam assembly of the present invention.

[0031] Figure 10 This is a schematic diagram of the front structure of the extruded preform of the beam assembly of the present invention.

[0032] In the picture:

[0033] 1. A tubular body with a porous structure;

[0034] 11. The first rectangular tube;

[0035] 12. The second rectangular tube;

[0036] 13. The third rectangular tube;

[0037] 14. The fourth rectangular tube;

[0038] 141. Sloping surface;

[0039] 15. Right triangle pipe body;

[0040] 16. Cantilevered pipe structure;

[0041] 17. The crossbeam assembly is missing a connecting part;

[0042] 18. Left port sealing plate;

[0043] 181. Left limit stop plate;

[0044] 1811. Left limit connecting edge;

[0045] 19. Right port sealing plate;

[0046] 191. Right limit stop plate;

[0047] 1911. Right limit connecting edge;

[0048] 2. T-shaped threaded sleeve;

[0049] 21. Circular base;

[0050] 22. Hollow tube body;

[0051] 3. Crossbeam assembly;

[0052] 31. A tube with a honeycomb structure;

[0053] 311. The first rectangular tube of the crossbeam;

[0054] 312. The second longest rectangular tube of the crossbeam;

[0055] 313. The third rectangular tube of the crossbeam;

[0056] 314. A long right-angled trapezoidal tube body with a crossbeam;

[0057] 315. The first square tube body of the beam;

[0058] 316. The second square tube of the crossbeam;

[0059] 317. Short right-angled trapezoidal tube body for crossbeams;

[0060] 318. The crossbeam is missing its connecting part;

[0061] 32. Oblique cut;

[0062] 33. Gap in the crossbeam;

[0063] 4. Beam frame assembly;

[0064] 41. Left longitudinal beam;

[0065] 42. Right longitudinal beam;

[0066] 43. Left spring support;

[0067] 44. Right spring support;

[0068] 45. Anti-collision beam;

[0069] 46. ​​Left support beam of the crash beam;

[0070] 47. Right-side support beam of the crash barrier;

[0071] 48. First crossbeam;

[0072] 49. Second crossbeam. Detailed Implementation

[0073] To make the technical problems solved by the present invention, the technical solutions adopted, and the technical effects achieved clearer, the technical solutions of the present invention will be further described below in conjunction with the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are merely for explaining the present invention and are not intended to limit the present invention. Furthermore, it should be noted that, for ease of description, only the parts related to the present invention are shown in the accompanying drawings, not all of them.

[0074] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. The terms "first position" and "second position" refer to two different positions.

[0075] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections or detachable connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal connections between two components. Those skilled in the art can understand the specific meaning of these terms in this invention based on the specific circumstances.

[0076] Example 1

[0077] See Figures 1-3 As shown, a torque box includes a tubular body 1 with a porous structure made of aluminum alloy and a T-shaped threaded sleeve 2.

[0078] The circumferential sidewalls of the porous tubular body 1 are planar, and the left and right ends of the porous tubular body 1 are irregular cuts composed of multiple continuous oblique cuts.

[0079] The T-shaped threaded sleeve 2 is vertically inserted and fixed between the upper and lower end faces of the porous tubular body 1, with the upper end of the T-shaped threaded sleeve 2 protruding outside the upper end face of the porous tubular body 1.

[0080] The porous tubular body 1 is formed and cut from aluminum profiles using an extrusion process.

[0081] The porous tubular body 1 has a first rectangular tube 11, a second rectangular tube 12, and a third rectangular tube 13 arranged vertically on its right side. To the left of these three tubes, an upper fourth rectangular tube 14 and a lower right-angled triangular tube 15 are provided. A cantilevered tube 16 extends outward from the upper left end of the right-angled triangular tube 15. A crossbeam assembly missing connection 17 is integrally formed on the lower right side of the second rectangular tube 12 and the right side of the third rectangular tube 13. The upper surface of the fourth rectangular tube 14 is higher than the upper surface of the first rectangular tube 11, and the upper right corner of the fourth rectangular tube 14 is inclined to the right. The inclined surface 141 is connected at its lower end to the left side of the upper end face of the first rectangular tube 11. The first rectangular tube 11, the second rectangular tube 12, and the third rectangular tube 13 have through holes at corresponding positions. The T-shaped threaded sleeve 2 includes a circular base 21 and a hollow tube 22 fixedly connected to the circular base 21. The inner wall of the hollow tube 22 is provided with internal threads. The hollow tube 22 passes through the through holes on the first rectangular tube 11, the second rectangular tube 12, and the third rectangular tube 13 respectively. The upper end of the hollow tube 22 is exposed outside the upper end face of the first rectangular tube 11, and the circular base 21 contacts and is welded to the lower end face of the third rectangular tube 13.

[0082] The left and right ends of the porous tubular body 1 are respectively fitted with a left end sealing plate 18 and a right end sealing plate 19. The left end sealing plate 18 and the right end sealing plate 19 extend upward from the left and right ends of the cantilever structure tubular body 16, respectively, with a left limiting baffle 181 and a right limiting baffle 191.

[0083] The lower rear end of the left limiting baffle 181 and the lower rear end of the right limiting baffle 191 are respectively bent outwards at the position of the missing connection part 17 of the crossbeam assembly, forming a left limiting connecting baffle 1811 and a right limiting connecting baffle 1911.

[0084] Example 2

[0085] See Figures 1-10 As shown, a floor beam structure with torsion boxes includes a crossbeam assembly 3, two torsion boxes, and a beam frame assembly 4; the rear ends of the two torsion boxes are respectively welded and fixed to the crossbeam assembly 3, and the rear ends of the beam frame assembly 4 are respectively welded and fixed to the front ends of the two torsion boxes.

[0086] The crossbeam assembly 3 includes a honeycomb structure tube 31 made of aluminum alloy. The circumferential sidewalls of the honeycomb structure tube 31 are flat, and the cross-section of the honeycomb structure tube 31 is L-shaped. The long arm of the L-shaped honeycomb structure tube 31 includes a first rectangular tube 311, a second rectangular tube 312, a third rectangular tube 313, and a long right-angled trapezoidal tube 314. The short arm of the L-shaped honeycomb structure tube 31 includes a first square tube 315. The second square tube 316 and the short right-angled trapezoidal tube 317 of the crossbeam, the first rectangular tube 311, the second rectangular tube 312, and the first square tube 315 of the crossbeam are arranged from top to bottom. The third rectangular tube 313 and the long right-angled trapezoidal tube 314 of the crossbeam are arranged vertically and located to the right of the first rectangular tube 311 and the second rectangular tube 312 of the crossbeam. The inclined surface at the bottom of the long right-angled trapezoidal tube 314 of the crossbeam is perpendicular to the short right angle of the crossbeam. The trapezoidal tube 317 is matched and joined at an angle. The short right-angled trapezoidal tube 317 and the second square tube 316 of the crossbeam are arranged vertically and located on the right side of the first square tube 315 of the crossbeam. The right side of the third rectangular tube 313 of the crossbeam, the right side of the long right-angled trapezoidal tube 314 of the crossbeam, and the upper end face of the short right-angled trapezoidal tube 317 of the crossbeam together form the missing connection part 318 of the crossbeam. The two ends of the honeycomb structure tube 31 are connected by the upper end face of the short right-angled trapezoidal tube 317 of the crossbeam. The tube 31 with honeycomb structure has symmetrical oblique cuts 32 at the bottom and downward. The front and rear side walls of the tube 31 have trapezoidal crossbeam notches 33 cut from the bottom to the top. The crossbeam assembly of the porous tube 1 of each torsion box is missing the connecting part 17 and is welded to the upper end face and front side face of the corresponding crossbeam assembly 3. The left limiting connecting edge 1811 and the right limiting connecting edge 1911 of each torsion box are respectively limited to contact and welded to the front side face of the crossbeam assembly 3.

[0087] The tube body 31 of the honeycomb structure is formed by extrusion of aluminum profiles and then cut.

[0088] The beam assembly 4 includes a left longitudinal beam 41, a right longitudinal beam 42, a left spring support 43, a right spring support 44, a bumper beam 45, a left support beam 46 for the bumper beam, a right support beam 47 for the bumper beam, a first cross beam 48 and a second cross beam 49; the bumper beam 45 has a structure with a straight middle part and horizontally curved ends at both ends. The front ends of the left longitudinal beam 41 and the right longitudinal beam 42 are respectively welded and fixed at the inner curved parts of the corresponding bumper beam 45. The first cross beam 48 and the second cross beam 49 are respectively welded and fixed between the left longitudinal beam 41 and the right longitudinal beam 42, and the second cross beam 49 is fixed at the rear ends of the corresponding side walls of the left longitudinal beam 41 and the right longitudinal beam 42. The left spring support 43 and the right spring support 44 are respectively symmetrically welded and fixed to the lower end surfaces of the left longitudinal beam 41 and the right longitudinal beam 42. One ends of the left support beam 46 for the bumper beam and the right support beam 47 for the bumper beam are respectively welded and fixed to the left end and the right end of the bumper beam 45, and the other ends of the left support beam 46 for the bumper beam and the right support beam 47 for the bumper beam are respectively welded and fixed to the outer side walls of the left longitudinal beam 41 and the right longitudinal beam 42. The rear ends of the left longitudinal beam 41 and the right longitudinal beam 42 are respectively seated on the upper end surfaces of the cantilever structure tube bodies 16 of the corresponding torsion boxes and welded and fixed, and the two side walls of the left longitudinal beam 41 and the right longitudinal beam 42 are respectively in limit contact with and welded and fixed to the left limit flanges 181 and the right limit flanges 191 of each torsion box.

[0089] The left longitudinal beam 41, the right longitudinal beam 42, the bumper beam 45, the left support beam 46 for the bumper beam, the right support beam 47 for the bumper beam, the first cross beam 48 and the second cross beam 49 are all formed by extrusion of aluminum profiles, and their cross-sections are all in the shape of "mouth", "day", "field" or "eye".

[0090] The left spring support 43 and the right spring support 44 are die-castings or sheet metal stamping parts.

[0091] Working principle

[0092] See Figures 1-3 As shown, according to the cross-section of the torsion box, by using the aluminum alloy extrusion forming process, an aluminum rod is extruded from an extrusion die to form a tubular blank with an equal cross-section, and then the processing boundary is cut out according to the design structure requirements of the torsion box, and the redundant parts on both sides are processed away (the processed waste can be completely recycled and reused), and finally various functional holes are processed to form the torsion box structure;

[0093] The black part in the cross-section represents the actual cross-section structure, and the white area inside the cross-section is a hollow structure. Different cross-section forms can be specifically adopted according to the requirements of the structure and performance; a lighter part structure and higher structural performance can be obtained through flexible cross-section structure optimization;

[0094] See Figures 4-10As shown, according to the cross-section of the beam assembly, the aluminum alloy extrusion forming process is used to extrude the aluminum rod from the extrusion die into a tubular blank with a uniform cross-section. Then, according to the design structure requirements of the beam assembly, the processing boundary is cut out, the two ends are cut with bevels, and the middle of the blank is cut from bottom to top to form a trapezoidal beam notch. The waste material from the cutting process can be completely recycled and reused. Finally, various functional holes are processed to form the beam assembly structure.

[0095] Although the invention has been specifically shown and described in conjunction with preferred embodiments, those skilled in the art should understand that various changes in form and detail may be made to the invention without departing from the spirit and scope of the invention as defined in the appended claims, all of which shall be within the scope of protection of the invention.

Claims

1. A torsion box, characterized in that: It includes a porous tubular body (1) made of aluminum alloy and a T-shaped threaded sleeve (2); The circumferential sidewalls of the porous tubular body (1) are planar, and the left and right ends of the porous tubular body (1) are irregular cuts composed of multiple continuous oblique cuts; The T-shaped threaded sleeve (2) is vertically inserted and fixed between the upper and lower end faces of the porous tubular body (1), and the upper end of the T-shaped threaded sleeve (2) is exposed outside the upper end face of the porous tubular body (1). The porous tubular body (1) has a first rectangular tube (11), a second rectangular tube (12), and a third rectangular tube (13) arranged vertically on the right side. The first rectangular tube (11), the second rectangular tube (12), and the third rectangular tube (13) arranged vertically have an upper fourth rectangular tube (14) and a lower right-angled triangular tube (15) on the left side. The upper left end of the right-angled triangular tube (15) has a cantilever structure tube (16) extending outward. The lower middle part of the right side of the second rectangular tube (12) and the right side of the third rectangular tube (13) are provided with a missing connection part (17) of the crossbeam assembly. The upper end face of the fourth rectangular tube (14) is higher than the upper end face of the first rectangular tube (11), and the upper right corner of the fourth rectangular tube (14) is provided with a right-sloping ramp. The lower end of the sloped surface (141) is connected to the left side of the upper end face of the first rectangular tube (11). The first rectangular tube (11), the second rectangular tube (12) and the third rectangular tube (13) are provided with through holes at corresponding positions. The T-shaped threaded sleeve (2) includes a circular base (21) and a hollow tube (22) fixedly connected to the circular base (21). The inner wall of the hollow tube (22) is provided with internal threads. The hollow tube (22) passes through the through holes on the first rectangular tube (11), the second rectangular tube (12) and the third rectangular tube (13) respectively. The upper end of the hollow tube (22) is exposed outside the upper end face of the first rectangular tube (11), and the circular base (21) contacts and is welded to the lower end face of the third rectangular tube (13).

2. A torque box according to claim 1, characterized in that: The porous tubular body (1) is formed and cut using an aluminum profile extrusion process.

3. A torque box according to claim 1, characterized in that: The left and right ends of the porous tubular body (1) are respectively encapsulated with a left end plate (18) and a right end plate (19). The left end plate (18) and the right end plate (19) extend upward from the left and right ends of the cantilever tubular body (16) respectively, with a left limiting baffle (181) and a right limiting baffle (191).

4. A torque box according to claim 3, characterized in that: The lower rear end of the left limiting baffle (181) and the lower rear end of the right limiting baffle (191) are respectively bent outwards at the position of the missing connecting part (17) of the crossbeam assembly, with left limiting connecting baffle (1811) and right limiting connecting baffle (1911).

5. A floor beam structure with a torsion box, characterized in that: It includes a crossbeam assembly (3) and a beam frame assembly (4), and also includes two torsion boxes as described in any one of claims 1-4; the rear ends of the two torsion boxes are respectively welded and fixed to the crossbeam assembly (3), and the rear ends of the beam frame assembly (4) are respectively welded and fixed to the front ends of the two torsion boxes.

6. A floor beam structure with a torsion box according to claim 5, characterized in that: The crossbeam assembly (3) includes a honeycomb structure tube (31) made of aluminum alloy. The circumferential sidewalls of the honeycomb structure tube (31) are flat. The cross-section of the honeycomb structure tube (31) is L-shaped. The long arm of the L-shaped honeycomb structure tube (31) includes a first rectangular tube (311), a second rectangular tube (312), a third rectangular tube (313), and a long right-angled trapezoidal tube (314). The short arm of the L-shaped honeycomb structure tube (31) includes a first square tube (311). 5) The second square tube of the crossbeam (316) and the short right-angled trapezoidal tube of the crossbeam (317), the first rectangular tube of the crossbeam (311), the second rectangular tube of the crossbeam (312), and the first square tube of the crossbeam (315) are arranged from top to bottom. The third rectangular tube of the crossbeam (313) and the long right-angled trapezoidal tube of the crossbeam (314) are arranged vertically and located to the right of the first rectangular tube of the crossbeam (311) and the second rectangular tube of the crossbeam (312). The inclined surface of the lower part of the long right-angled trapezoidal tube of the crossbeam (314) is connected to the short right-angled trapezoidal tube of the crossbeam. The inclined surfaces of the right-angled trapezoidal tubes (317) are matched and joined. The short right-angled trapezoidal tubes (317) and the second square tubes (316) of the crossbeam are arranged vertically and set on the right side of the first square tube (315) of the crossbeam. The right side of the third rectangular tube (313) of the crossbeam, the right side of the long right-angled trapezoidal tube (314) of the crossbeam, and the upper end of the short right-angled trapezoidal tube (317) of the crossbeam together form the missing connection part (318) of the crossbeam. The two ends of the tubes (31) of the honeycomb structure are connected by the short right-angled trapezoidal tubes (317) of the crossbeam. The end face is symmetrically provided with oblique cuts (32) facing downwards. The front and rear side walls of the honeycomb structure tube (31) are cut with trapezoidal crossbeam notches (33) from the bottom to the top. The crossbeam assembly of the porous structure tube (1) of each torsion box is missing the connecting part (17) and is welded to the upper end face and front side face of the corresponding crossbeam assembly (3). The left limiting connecting edge (1811) and the right limiting connecting edge (1911) of each torsion box are respectively limited to contact and welded to the front side face of the crossbeam assembly (3).

7. A floor beam structure with a torsion box according to claim 6, characterized in that: The tube body (31) of the honeycomb structure is formed and cut by aluminum profile extrusion process.

8. A floor beam structure with a torsion box according to claim 5, characterized in that: The beam assembly (4) includes a left longitudinal beam (41), a right longitudinal beam (42), a left spring support (43), a right spring support (44), a bumper beam (45), a left support beam of the bumper beam (46), a right support beam of the bumper beam (47), a first cross beam (48) and a second cross beam (49); the bumper beam (45) has a structure with a straight middle and horizontally curved ends; the front ends of the left longitudinal beam (41) and the right longitudinal beam (42) are respectively welded and fixed at the inner arc bending parts of the corresponding bumper beam (45); the first cross beam (48) and the second cross beam (49) are respectively welded and fixed between the left longitudinal beam (41) and the right longitudinal beam (42), and the second cross beam (49) is fixed at the rear ends of the corresponding side walls of the left longitudinal beam (41) and the right longitudinal beam (42); the left spring support (43) and the right spring support (44) are respectively symmetrically welded and fixed on the lower end surfaces of the left longitudinal beam (41) and the right longitudinal beam (42); one ends of the left support beam of the bumper beam (46) and the right support beam of the bumper beam (47) are respectively welded and fixed at the left end and the right end of the bumper beam (45), and the other ends of the left support beam of the bumper beam (46) and the right support beam of the bumper beam (47) are respectively welded and fixed on the outer side walls of the left longitudinal beam (41) and the right longitudinal beam (42); the rear ends of the left longitudinal beam (41) and the right longitudinal beam (42) are respectively seated on the upper end surfaces of the cantilever structure tubes (16) of the corresponding torsion boxes and welded and fixed, and the two side walls of the left longitudinal beam (41) and the right longitudinal beam (42) are respectively in limit contact with and welded and fixed to the left limit flanges (181) and the right limit flanges (191) of each torsion box.

9. A floor beam structure with a torsion box according to claim 8, characterized in that: The left longitudinal beam (41), the right longitudinal beam (42), the bumper beam (45), the left support beam of the bumper beam (46), the right support beam of the bumper beam (47), the first cross beam (48) and the second cross beam (49) are all formed by an aluminum profile extrusion process, and their cross-sections are all in the shape of "mouth", "day", "field" or "eye".

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