A commercial vehicle hybrid material instrument cross beam and a manufacturing method thereof

Abstract

The application relates to a commercial vehicle mixed material instrument beam and a manufacturing method thereof, wherein an aluminum alloy pipe beam cross section is polygonal; a steering column support and a main driver side front wall and a steering column integrated support support are formed by magnesium-aluminum alloy pressure casting, and are connected with the aluminum alloy pipe beam through FDS screws; a plastic support assembly is segmented injection molded, each segment comprises a support body and a plastic connecting ring connected with each other; an inner wall of the plastic connecting ring is provided with a cladding connecting surface for the outer surface of the aluminum alloy pipe beam; and the plastic connecting ring and the aluminum alloy pipe beam are pull-riveted. The above structure realizes that the stamping and welding process can be replaced by the FDS and pull-riveting processes, the production cost and steps are reduced; the plastic connecting ring increases the connecting area, directly contacts the aluminum alloy pipe beam through an opening during connection, and is riveted; the connecting strength is strengthened while installation and positioning are facilitated; the injection molding is performed in a segmented mode, the mold scale is reduced, and the injection molding process and cost are simplified.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of vehicle instrument panel beam assemblies, in particular to a commercial vehicle hybrid material instrument panel beam and a manufacturing method thereof. BACKGROUND

[0002] In the process of new energy commercial vehicles, with the introduction of new functions and various electrical appliances, the instrument panel beam bears greater load and brings greater lightweight pressure. The existing instrument panel beam lightweight technology mainly includes single material instrument panel beam and hybrid material instrument panel beam according to the material classification.

[0003] The single material instrument panel beam mainly includes the following types:

[0004] I. Traditional steel stamping and welding instrument panel beam, which is currently the most widely used due to its low cost. However, it has the following significant disadvantages: heavy weight, complex welding process, uneven welding quality, and low production efficiency.

[0005] II. Aluminum alloy stamping and welding or riveting instrument panel beam, which has good lightweight effect but high cost. It also has the defects of multiple welding or connecting points and low production efficiency.

[0006] III. Magnesium alloy integral die-casting instrument panel beam, which has the advantages of integrated design and high production efficiency, suitable for single model mass production. However, this method has high cost, large initial investment, and low lightweight effect.

[0007] IV. Full plastic instrument panel beam, as described in CN 111216378 A. However, this method is relatively simple for passenger vehicle instrument panel beams, but it is difficult to implement for commercial vehicle instrument panel assemblies with complex structures. The product has poor dimensional stability at high temperatures, and the strength and rigidity cannot be guaranteed. Therefore, this method is not suitable for commercial vehicle instrument panel beams with complex structures and high strength requirements.

[0008] The hybrid material instrument panel beam mainly includes the following types:

[0009] Aluminum-plastic material instrument panel beam, as described in CN 217804944 U. However, this method uses an elliptical cross-section for the aluminum alloy main beam, which makes it difficult to ensure accurate positioning when connecting the front wall support to the main beam with bolts. The plastic support and aluminum alloy main beam are connected through an in-mold injection molding process, which has the following defects: complex mold design, high mold manufacturing cost, difficult process, and additional knurling process on the main beam surface. Therefore, this method is not suitable for commercial vehicle instrument panel beams with complex structures, high strength requirements, and relatively small batch sizes.

[0010] Therefore, a new structure is needed to solve the above problems. SUMMARY

[0011] The embodiment of the application provides a commercial vehicle mixed material instrument beam and a manufacturing method thereof, so as to solve the problem that the aluminum alloy main beam of the aluminum plastic material instrument beam adopts an elliptical section, so that it is difficult to ensure positioning accuracy when a front wall connecting support is bolted with the main beam; and the problem that for a commercial vehicle instrument beam with a complex structure, a mold design is complex, a mold manufacturing cost is high, a process is difficult, and a knurling process is added on the surface of the main beam.

[0012] In a first aspect, a commercial vehicle mixed material instrument beam is provided, comprising:

[0013] An aluminum alloy pipe beam, a cross section of which is a polygon;

[0014] A steering column support is formed by magnesium-aluminum alloy pressure casting and connected with the aluminum alloy pipe beam through FDS screws;

[0015] A main driver side front wall and steering column integrated support support is formed by magnesium-aluminum alloy pressure casting and connected with the aluminum alloy pipe beam through FDS screws;

[0016] A plastic support assembly is formed by sectional injection molding; each section of the plastic support assembly comprises a support body and a plastic connecting ring connected with each other; an inner wall of the plastic connecting ring is provided with a connecting surface for covering an outer surface of the aluminum alloy pipe beam; the plastic connecting ring is further provided with an opening for the aluminum alloy pipe beam to enter the inside of the plastic connecting ring; and the plastic connecting ring is pull-riveted with the aluminum alloy pipe beam.

[0017] In some embodiments, the multiple sections of the plastic support assembly are independent support structures, and the types of the support structures include a left side wall connecting support, a right side wall connecting support, an electrical appliance mounting support, a middle channel floor connecting support, a co-driver side front wall connecting support and a reinforcing support.

[0018] In some embodiments, the plastic connecting ring extends in the extension direction of the aluminum alloy pipe beam, and is further provided with a positioning hole and a connecting hole; and the aluminum alloy pipe beam is also provided with the positioning hole and the connecting hole.

[0019] The plastic connecting ring is connected with the aluminum alloy pipe beam through cooperation of the positioning pin and the positioning hole and cooperation of the draw core rivet and the connecting hole.

[0020] In some embodiments, an adhesive layer is arranged between the inner wall of the plastic connecting ring and the outer surface area of the aluminum alloy pipe beam.

[0021] In some embodiments, the plastic connecting ring is further provided with a hollow weight-reducing hole.

[0022] In some embodiments, the cross section of the aluminum alloy pipe beam is octagonal, and the cross section of the inner wall of the plastic connecting ring is also octagonal.

[0023] In some embodiments, the end of the bracket body away from the plastic connecting ring is injection molded with a metal insert.

[0024] In some embodiments, the aluminum alloy pipe beam, the steering column bracket, and the main driver side front wall and steering column integrated support bracket are each provided with a threaded hole matching the FDS screw.

[0025] In some embodiments, the aluminum alloy pipe beam is provided with a metal connecting ring having the same structure as the plastic connecting ring.

[0026] The steering column bracket and the main driver side front wall and steering column integrated support bracket are connected to the metal connecting ring through the FDS screw.

[0027] In a second aspect, a manufacturing method of a commercial vehicle mixed material instrument transverse beam is provided, characterized in that the method comprises:

[0028] The structure and size of each section of the plastic bracket assembly are obtained, and the plastic bracket assembly is manufactured by sectional injection molding according to the structure and size;

[0029] The target shape and size of the aluminum alloy pipe beam, the steering column bracket, and the main driver side front wall and steering column integrated support bracket are obtained, and the aluminum alloy pipe beam, the steering column bracket, and the main driver side front wall and steering column integrated support bracket are manufactured according to the target shape and size;

[0030] The steering column bracket and the main driver side front wall and steering column integrated support bracket are connected to the aluminum alloy pipe beam through the FDS screw, and the plastic connecting ring is connected to the aluminum alloy pipe beam.

[0031] The technical scheme provided by the application has the following beneficial effects:

[0032] The embodiments of the application provide a commercial vehicle mixed material instrument transverse beam and a manufacturing method thereof. Since the cross section of the aluminum alloy pipe beam is polygonal, the steering column bracket is made of magnesium-aluminum alloy and is connected to the aluminum alloy pipe beam through the FDS screw, the main driver side front wall and steering column integrated support bracket is made of magnesium-aluminum alloy and is connected to the aluminum alloy pipe beam through the FDS screw, the plastic bracket assembly is manufactured by sectional injection molding, each section of the plastic bracket assembly comprises a bracket body and a plastic connecting ring connected to each other, the plastic connecting ring has an inner wall provided with a connecting surface covering and abutting the outer surface of the aluminum alloy pipe beam, the plastic connecting ring is further provided with an opening for the aluminum alloy pipe beam to enter the inside of the plastic connecting ring, and the plastic connecting ring is connected to the aluminum alloy pipe beam through rivet connection.

[0033] The above structure allows for the replacement of stamping and welding processes with FDS and riveting, reducing production costs and steps. Furthermore, since only the steering column bracket and the driver's side front bulkhead and steering column integrated support bracket are metal, while the rest of the brackets are made of plastic, weight is significantly reduced. Additionally, the plastic connecting ring and the aluminum alloy tube beam have matching polygonal cross-sections; the plastic connecting ring increases the connection area, allowing direct contact with the aluminum alloy tube beam through the opening before riveting. This facilitates installation and positioning while strengthening the connection, avoiding the additional costs associated with knurling and processing the aluminum tube surface, reducing the number of parts and connection points, and improving the dimensional accuracy of parts and the efficiency of assembly. Moreover, the plastic bracket components are injection molded in segments, reducing mold size, simplifying the injection molding process, and minimizing investment in local design changes and mold replacements. Attached Figure Description

[0034] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0035] Figure 1 The overall structure of the hybrid material instrument beam for commercial vehicles provided in this application embodiment;

[0036] Figure 2 A schematic diagram of the structure of the plastic connecting ring installed on the aluminum alloy tube beam according to an embodiment of this application;

[0037] Figure 3 A schematic cross-sectional view of a plastic connecting ring installed on an aluminum alloy tube beam, as provided in an embodiment of this application.

[0038] In the diagram: 1. Aluminum alloy tube beam; 2. Steering column bracket; 3. Plastic connecting ring; 4. Left side panel connecting bracket; 5. Right side panel connecting bracket; 6. Electrical mounting bracket; 7. Driver's side front panel and steering column integrated support bracket; 8. Center tunnel floor connecting bracket; 9. Passenger side front panel connecting bracket; 10. Metal insert; 11. FDS screw; 12. Reinforcing bracket; 13. Blind rivet. Detailed Implementation

[0039] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0040] This application provides a hybrid material instrument beam for commercial vehicles and its manufacturing method, to solve the problems in related technologies where the aluminum alloy main beam of the aluminum-plastic material instrument beam has an elliptical cross section, making it difficult to ensure accurate positioning when the front connecting bracket is bolted to the main beam; and the defects of the process of connecting each plastic bracket to the aluminum alloy main beam by injection molding, which is complex for commercial vehicle instrument beams with complex structures, such as complex mold design, high mold manufacturing cost, high process difficulty, and additional knurling process on the surface of the main beam.

[0041] Please see Figures 1-3 A hybrid material instrument crossbeam for commercial vehicles, comprising:

[0042] Aluminum alloy tube beam 1, its cross-section is polygonal;

[0043] The steering column bracket 2 is made of magnesium-aluminum alloy by die casting and is connected to the aluminum alloy tube beam 1 by FDS screw 11;

[0044] The driver's side front bulkhead and steering column integrated support bracket 7 is made of magnesium-aluminum alloy die casting and is connected to the aluminum alloy tube beam 1 by FDS screws 11.

[0045] The plastic support assembly is injection molded in segments; each segment of the plastic support assembly includes a support body and a plastic connecting ring 3 connected together; the plastic connecting ring 3 has an inner wall with a connecting surface that covers and fits the outer surface of the aluminum alloy tube beam 1; the plastic connecting ring 3 also has an opening for the aluminum alloy tube beam 1 to enter its interior; the plastic connecting ring 3 is riveted to the aluminum alloy tube beam 1.

[0046] The above structural design offers the following advantages during the production, installation, and manufacturing process:

[0047] First, the steering column bracket 2 and the driver's side front bulkhead and steering column integrated support bracket 7 are connected to the aluminum alloy tube beam 1 by FDS screws 11. The plastic bracket assembly is riveted to the aluminum alloy tube beam 1 by its plastic connecting ring 3. This allows the FDS and riveting process to replace the stamping and welding process, reducing production costs and steps.

[0048] In addition, since only the steering column bracket 2 and the driver's side front bulkhead and steering column integrated support bracket 7 are made of metal, while the rest of the brackets are made of plastic, the weight is greatly reduced.

[0049] Furthermore, the cross-sections of the plastic connecting ring 3 and the aluminum alloy tube beam 1 are both compatible polygons. The plastic connecting ring 3 covers the outside of the aluminum alloy tube beam 1, increasing the connection area and strengthening the connection between the beam and the aluminum alloy tube beam 1. In particular, the plastic connecting ring 3 increases the stiffness and strength required for the entire aluminum alloy tube beam 1, which can correspondingly reduce the wall thickness of the aluminum alloy tube beam 1, and reduce its diameter and weight.

[0050] During connection, positioning can be completed by directly contacting the aluminum alloy tube beam through the opening, followed by riveting. This facilitates installation and positioning while strengthening the connection, avoiding the additional costs incurred by knurling and processing the aluminum tube surface, reducing the number of parts and connection points, and improving the dimensional accuracy of parts and the efficiency of assembly.

[0051] The plastic bracket assembly is injection molded in segments, which reduces the size of the mold, simplifies the injection molding process, and reduces the investment required for local design changes and mold replacements.

[0052] In some preferred embodiments, the multiple segments of the plastic bracket assembly are independent bracket structures. These bracket structures include a left side panel connecting bracket 4, a right side panel connecting bracket 5, an electrical mounting bracket 6, a center console floor connecting bracket 8, a passenger-side front panel connecting bracket 9, a reinforcing bracket 12, and a central screen mounting bracket. The electrical mounting bracket 6 and the central screen mounting bracket are arranged side-by-side, integrating their mounting points to control the relative tolerances between them, thereby ensuring the gap between the instrument panel frame and the central screen remains within the design range.

[0053] In some preferred embodiments, the specific riveting method of the plastic connecting ring 3 is described in detail:

[0054] The plastic connecting ring 3 extends in the extension direction of the aluminum alloy tube beam 1, and is provided with positioning holes and connecting holes; the aluminum alloy tube beam 1 is also provided with positioning holes and connecting holes; the plastic connecting ring 3 is connected to the aluminum alloy tube beam 1 through the cooperation of positioning pin and positioning hole, and the cooperation of core-pulling rivet 13 and connecting hole riveting.

[0055] Furthermore, to enhance the connection strength, an adhesive layer is provided between the inner wall of the plastic connecting ring 3 and the outer surface of the aluminum alloy tube beam 1. The adhesive is a two-component polyurethane adhesive with a component ratio of A to B of 1:1 and a film thickness of 9mm to 10mm.

[0056] Furthermore, the plastic connecting ring 3 is also provided with hollowed-out weight-reduction holes to ensure the lightweight characteristics. The above structural description describes the specific form of connection, indicating that the length of the plastic connecting ring 3 can be appropriately increased to improve the rigidity and strength required by the entire aluminum alloy tube beam 1, thereby correspondingly reducing the wall thickness of the aluminum alloy tube beam 1 and reducing its diameter and weight.

[0057] In some preferred embodiments, the most preferred solution in this application is: the aluminum alloy tube beam 1 has an octagonal cross-section, and the inner wall of the plastic connecting ring 3 also has an octagonal cross-section; the end of the bracket body away from the plastic connecting ring 3 is injection molded with a metal insert 10; the metal insert 10 facilitates connection with other vehicle accessories. The octagonal cross-section of the aluminum alloy tube beam 1 is a regular octagonal tube beam cross-section structure, which has better bending processing stability than U-shaped or elliptical cross-section beams. At the same time, it can ensure that the aluminum profile beam and the plastic bracket have a relatively high connection strength and precision, avoiding the additional costs increased by introducing surface knurling and processing procedures on the aluminum tube.

[0058] In some preferred embodiments, the connection of the aluminum alloy tube beam 1, the steering column bracket 2, and the driver's side front bulkhead and steering column integrated support bracket 7 is described:

[0059] The first type involves threaded holes on the aluminum alloy tube beam 1, the steering column bracket 2, and the driver's side front bulkhead and steering column integrated support bracket 7, all of which are equipped with threads that match the FDS screw 11. This method allows for direct connection to the aluminum alloy tube beam 1.

[0060] The second method involves an aluminum alloy tube beam 1 with a metal connecting ring having the same structure as the plastic connecting ring 3; the steering column bracket 2 and the driver's side front bulkhead and steering column integrated support bracket 7 are connected to the metal connecting ring via FDS screws 11; the connection method between the metal connecting ring and the aluminum alloy tube beam 1 is the same as the connection method of the plastic connecting ring 3. This method is an indirect connection. The second method is preferred in this application.

[0061] This application also proposes a method for manufacturing a hybrid material instrument crossbeam for commercial vehicles, which includes the following steps:

[0062] Obtain the structure and dimensions of each segment of the plastic support assembly, and perform segmented injection molding according to the structure and dimensions; in addition to dividing each segment according to its function, CAE analysis can also be used to analyze its stress, determine the segmented area, and determine the dimensions of the plastic connecting ring 3 in each segment, namely the wall thickness and length.

[0063] Obtain the target shape and dimensions of aluminum alloy tube beam 1, steering column bracket 2, and driver's side front bulkhead and steering column integrated support bracket 7; then manufacture aluminum alloy tube beam 1, steering column bracket 2, and driver's side front bulkhead and steering column integrated support bracket 7 according to the target shape and dimensions.

[0064] The steering column bracket 2 and the driver's side front bulkhead and steering column integrated support bracket 7 are connected to the aluminum alloy tube beam 1 using FDS screws 11; at the same time, the plastic connecting ring 3 is connected to the aluminum alloy tube beam 1.

[0065] The following is a detailed explanation of the precautions and specific steps involved in the manufacturing process:

[0066] Structure and materials used:

[0067] 1. The aluminum alloy tube beam 1 is made of Al-6061-T6 polygonal profile tube beam with an outer circumscribed circle diameter of Φ45mm and a wall thickness of 2.5mm. The steering column bracket 2 and the driver's side front bulkhead and steering column integrated support bracket 7 are made of die-cast magnesium alloy AZ91D material and are connected to the aluminum alloy tube beam 1 by FDS screws 11 (M5x22) 4. Through CAE analysis, the plastic bracket assembly is divided into multiple sections and is mainly composed of left side bulkhead connecting bracket 4, right side bulkhead connecting bracket 5, electrical installation bracket 6, center tunnel floor connecting bracket 8, passenger side front bulkhead connecting bracket 9, and central screen installation bracket. Then, it is positioned and wrapped on the aluminum alloy tube beam 1 by plastic connecting rings 3 and connected and fixed with (M6 or M8) blind rivets 13. The plastic material is PA6+GF50.

[0068] The metal inserts 10 at the ends of all plastic bracket bodies are nuts, which are injection molded and encased inside the bracket body.

[0069] Through the above material and structural design, the weight is reduced by 53% compared to existing steel stamped and welded instrument beams, which is superior to other instrument beam structures. It also has a cost advantage of approximately 25% compared to aluminum alloy or magnesium alloy structural beams.

[0070] II. Main molding process parameters:

[0071] I. The bending process of the polygonal profile tube beam adopts the cold drawing bending process with a ball head elastic core pulling mechanism. Before bending, the main beam material is 6061-T4 state. The bending is completed at 4 points according to the design requirements through end positioning. The bending rate of each point is 3 seconds. The bending angle should fully analyze the material springback (actual measurement 10%~12%). The bent parts are heat treated at 175℃~185℃ for (5~6) hours. The material is stabilized in 6061-T6 state. The minimum bending radius of the formed parts is 77mm, the maximum bending radius is 125.16mm, the wall thickness thinning is ≤10%, and the collapse rate is controlled at about 1%, which fully meets the design requirements.

[0072] II. The multi-stage injection molding process for the plastic bracket assembly has a maximum moisture content of ≤0.05% after drying, a preheating temperature of 130℃~140℃ for the metal inserts, a melting temperature of 270℃~305℃, a mold preheating temperature of 60℃, an injection pressure (maximum) of 95 bar, a total molding cycle of 120 seconds, and a dimensional accuracy of ±(0.1%~0.5%) for the molded parts, meeting the design requirements.

[0073] III. Manufacturing process of steering column bracket 2 and driver's side front bulkhead and steering column integrated support bracket 7; material AZ91D, high speed and high pressure injection into metal cavity for rapid forming in molten state, mold temperature: 210℃, pouring temperature: 660℃; pressure: 30MPa~40MPa, speed: ingate speed 90m / sec, casting filling time 7ms.

[0074] IV. The 13-stage riveting connection process using blind rivets involves pre-installed positioning pins, positioning holes, and connection holes on the segmented plastic bracket assembly and aluminum alloy tube beam 1. A two-component polyurethane adhesive is used, with a 1:1 ratio of components A and B. The adhesive film thickness is 9mm–10mm. The working time (20g / min, 30℃) is 45min, followed by a 30min pre-curing period. The curing time after riveting (80℃) is 6h.

[0075] The V-FDS connection process has a maximum torque of 6 Nm, a depth of 17-25 mm, and a maximum step time of 2 seconds. Flow drilling: 8000 RPM; cutter head cylinder pressure 0.6 KN; acceleration / deceleration time 0.1 s. RSF screw insertion: 3000 RPM; cutter head cylinder pressure 0.8 KN; acceleration / deceleration time 0.1 s. RSF tightening: 180 RPM; cutter head cylinder pressure 0.75 KN; acceleration / deceleration time 0.1 s; torque 5.5 Nm.

[0076] In summary, this application has the following advantages:

[0077] (1) The main body of the aluminum alloy tube beam 1 is a regular octagonal tube beam cross section structure. The bending processing stability is better than that of U-shaped or elliptical cross section beams. At the same time, it can ensure that the aluminum profile beam and the plastic bracket have a relatively high connection strength and precision, avoiding the additional cost of introducing the surface knurling and processing of aluminum tubes.

[0078] (2) The structural design of the plastic connecting ring 3 improves the rigidity and strength required for the entire aluminum alloy tube beam 1, which can correspondingly reduce its cross-sectional wall thickness, diameter and weight, and avoid the use of segmented structure due to the different strength requirements of the driver and passenger seat crossbeams. On the basis of ensuring connection strength, the number of parts and connection points is reduced, and the dimensional accuracy of parts and the efficiency of assembly are improved.

[0079] (3) The plastic bracket assembly is reasonably modularized and segmented according to different reinforcement requirements, bracket functions and the ease of mold injection and demolding. This can reduce the size of the mold, simplify the injection molding process, and reduce the investment caused by local design changes and mold replacement. The segmented plastic bracket assembly and the aluminum alloy tube beam 1 are positioned by positioning pins and adhesive bonding, and are connected and fixed by riveting process. This combination completely replaces the welding process, which can greatly reduce the investment in tooling and molds, simplify the injection molding process, improve the quality of injection molded parts, and effectively reduce the manufacturing cost of parts.

[0080] (4) The cold drawing and bending process of tube beams, the selection and treatment of different states of 6061 aluminum alloy before and after bending, take into account both the performance of the parts and the processing dimensional accuracy.

[0081] In the description of this application, it should be noted that the terms "upper," "lower," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and 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, and therefore should not be construed as a limitation of this application. Unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two elements. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0082] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0083] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1The function specified in one or more boxes.

[0084] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the functions specified in one or more boxes. In a typical configuration, a computing device includes one or more processors (CPU), input / output interfaces, network interfaces, and memory. Memory may include non-persistent memory in computer-readable media, random access memory (RAM), and / or non-volatile memory, such as read-only memory (ROM) or flash RAM. Memory is an example of computer-readable media.

[0085] Computer-readable media, including both permanent and non-permanent, removable and non-removable media, can store information using any method or technology. Information can be computer-readable instructions, data structures, program modules, or other data.

[0086] Examples of computer storage media include, but are not limited to, phase-change memory (PRAM), static random access memory (SRAM), dynamic random access memory (DRAM), other types of random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technologies, CD-ROM, digital versatile optical disc (DVD) or other optical storage, magnetic tape, magnetic magnetic disk storage or other magnetic storage devices, or any other non-transfer medium that can be used to store information accessible by a computing device. As defined herein, computer-readable media does not include transient media, such as modulated data signals and carrier waves. It should also be noted that the terms "comprising," "including," or any other variations thereof are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. In the absence of further restrictions, an element defined by the phrase "including one..." does not exclude the presence of other identical elements in the process, method, goods or equipment that include the element.

[0087] It should be noted that in this application, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0088] The above description is merely a specific embodiment of this application, enabling those skilled in the art to understand or implement this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

Claims

1. A hybrid material instrument crossbeam for commercial vehicles, characterized in that, It includes: Aluminum alloy tube beam (1); The steering column bracket (2) is made of magnesium-aluminum alloy die casting and is connected to the aluminum alloy tube beam (1) by FDS screws (11); The driver's side front bulkhead and steering column integrated support bracket (7) is made of magnesium-aluminum alloy die casting and is connected to the aluminum alloy tube beam (1) by FDS screws (11); The plastic support assembly is injection molded in segments; each segment of the plastic support assembly includes a support body and a plastic connecting ring (3) connected together; the inner wall of the plastic connecting ring (3) is provided with a connecting surface that covers the outer surface of the aluminum alloy tube beam (1); the plastic connecting ring (3) is also provided with an opening for the aluminum alloy tube beam (1) to enter its interior; the plastic connecting ring (3) is riveted to the aluminum alloy tube beam (1); The cross-section of the aluminum alloy tube beam (1) is octagonal, and the cross-section of the inner wall of the plastic connecting ring (3) is also octagonal.

2. The commercial vehicle hybrid material instrument crossbeam as described in claim 1, characterized in that: The plastic bracket assembly consists of multiple independent bracket structures, including left side panel connecting bracket (4), right side panel connecting bracket (5), electrical installation bracket (6), center channel floor connecting bracket (8), passenger side front panel connecting bracket (9), and reinforcement bracket (12).

3. The commercial vehicle hybrid material instrument crossbeam as described in claim 1, characterized in that: The plastic connecting ring (3) extends in the extension direction of the aluminum alloy tube beam (1) and is provided with positioning holes and connecting holes; the aluminum alloy tube beam (1) is also provided with positioning holes and connecting holes. The plastic connecting ring (3) is connected to the aluminum alloy tube beam (1) through the cooperation of the positioning pin and the positioning hole, and the cooperation of the core-pulling rivet (13) and the connecting hole.

4. The commercial vehicle hybrid material instrument crossbeam as described in claim 3, characterized in that: An adhesive layer is provided between the inner wall of the plastic connecting ring (3) and the outer surface area of ​​the aluminum alloy tube beam (1).

5. The commercial vehicle hybrid material instrument crossbeam as described in claim 3, characterized in that: The plastic connecting ring (3) is also provided with hollowed-out weight-reduction holes.

6. The commercial vehicle hybrid material instrument crossbeam as described in claim 1, characterized in that: The end of the bracket body away from the plastic connecting ring (3) is injection molded with a metal insert (10).

7. The commercial vehicle hybrid material instrument crossbeam as described in claim 1, characterized in that: The aluminum alloy tube beam (1), the steering column bracket (2), and the driver's side front bulkhead and steering column integrated support bracket (7) are all provided with threaded holes that match the FDS screw (11).

8. The commercial vehicle hybrid material instrument crossbeam as described in claim 1, characterized in that: The aluminum alloy tube beam (1) is provided with a metal connecting ring with the same structure as the plastic connecting ring (3); The steering column bracket (2) and the driver's side front bulkhead and steering column integrated support bracket (7) are connected to the metal connecting ring by FDS screws (11).

9. A method for manufacturing a hybrid material instrument crossbeam for commercial vehicles as described in claim 1, characterized in that, It includes: Obtain the structure and dimensions of each segment of the plastic support assembly, and manufacture the assembly by injection molding in segments according to the structure and dimensions; Obtain the target shape and size of the aluminum alloy tube beam (1), the steering column bracket (2), and the driver's side front bulkhead and steering column integrated support bracket (7); then manufacture the aluminum alloy tube beam (1), the steering column bracket (2), and the driver's side front bulkhead and steering column integrated support bracket (7) according to the target shape and size. The steering column bracket (2) and the driver's side front bulkhead and steering column integrated support bracket (7) are connected to the aluminum alloy tube beam (1) using FDS screws (11); at the same time, the plastic connecting ring (3) is connected to the aluminum alloy tube beam (1).

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