Manufacturing method of wedge-shaped low-wind-resistance cab

Abstract

The invention relates to a method for manufacturing a wedge-shaped low-wind-resistance cab, which comprises the following steps of: manufacturing a front wall assembly, a side wall assembly and a vehicle door assembly of the cab by utilizing an original production platform; according to the structural requirements of the wedge-shaped low-wind-resistance cab, a corresponding top cover assembly, a corresponding rear wall assembly and a corresponding bottom plate assembly are manufactured; and the side wall assembly and the vehicle door assembly are rotated by 3 degrees around the A column, the corresponding front wall assembly, the corresponding top cover assembly, the corresponding rear wall assembly and the corresponding bottom plate assembly are assembled, and the wedge-shaped low-wind-resistance cab is obtained. According to the invention, different cabs can be manufactured according to requirements while the cost is saved.

Description

Technical Field

[0001] The invention relates to the field of structural technology, and in particular to a method for manufacturing a wedge-shaped low-wind resistance cab. Background Art

[0002] The most effective way for new energy heavy trucks to reduce energy consumption is to reduce wind resistance. When a 49-ton 6-axle semi-trailer train travels at a speed of 90km / h, 30% of the power is used to overcome wind resistance. The current drag coefficient of mainstream flat-head heavy trucks is 0.52-0.62. In recent years, Chinese heavy truck companies have invested a lot of energy in reducing wind resistance, and have developed models with lower wind resistance through CFD analysis and wind tunnel tests.

[0003] The cab A of the low wind resistance model currently on the market (such as Figure 1 As shown in the figure, most of them are newly developed, from streamlined exterior styling to low wind resistance body-in-white. The development of a new body will incur huge investment. After searching, the patent: A cab manufacturing method and cab universal connection structure (CN202210346093.8) uses the original production platform to manufacture the lower structure of the cab without a top cover, and uses the lower structure of the cab as a universal structure; according to different vehicle needs, corresponding types of top covers and interface components compatible with each type of top cover are manufactured; from different types of top covers, corresponding top covers and interface components are selected, and the top cover and the universal structure are assembled using the interface component to obtain a cab. In the above patents, the reduction of wind resistance is achieved only by changing the top cover, and the relative change in wind resistance is not significant. Summary of the invention

[0004] In order to solve the above technical problems, the object of the present invention is to provide a method for manufacturing a wedge-shaped low wind resistance cab.

[0005] To achieve the above object, the present invention adopts the following technical solution:

[0006] A method for manufacturing a wedge-shaped low wind resistance cab comprises the following steps:

[0007] Using the original production platform, the cab's front panel assembly, side panel assembly and door assembly are manufactured;

[0008] According to the structural requirements of the wedge-shaped low wind resistance cab, the corresponding top cover assembly, rear enclosure assembly and bottom plate assembly are manufactured;

[0009] The side panel assembly and the door assembly are rotated 3° around the A-pillar, and the corresponding front panel assembly, top cover assembly, rear panel assembly and bottom panel assembly are assembled to obtain a wedge-shaped low-wind-drag cab.

[0010] Preferably, in the method for manufacturing a wedge-shaped low wind resistance cab, in the roof assembly:

[0011] The left and right top covers are rotated 3° along with the side panel assembly and are manufactured using the original production platform;

[0012] The front roof is manufactured on the original production platform. During installation, the front roof is shaped and welded according to the side roof.

[0013] The rear top cover is redeveloped and manufactured according to the positions of the left and right top covers;

[0014] The top cover frame is manufactured using the original production platform, wherein the left and right cross beams in the top cover frame that contact the left and right top covers are lengthened so as to contact the corresponding left and right top covers;

[0015] The middle top cover is developed and manufactured based on the original middle top cover, so that the new middle top cover can be restored to the original middle top cover structure after being cut along the cutting line.

[0016] Preferably, in the method for manufacturing a wedge-shaped low wind resistance cab, the middle top cover has two states:

[0017] 1) The middle roof cover is not cut, with dimensions of 1410×1774×180, and is mounted on a wedge-shaped low wind resistance cab;

[0018] 2) The middle top cover is cut to size 1410×1574×180 and is installed on the original platform cab.

[0019] Preferably, in the method for manufacturing a wedge-shaped low wind resistance cab, in the rear enclosure assembly:

[0020] The rear panel frame is manufactured using the original production platform, and the joint between the rear panel frame and the side panel assembly is remanufactured according to the location of the side panel assembly;

[0021] The rear outer panel is developed and manufactured based on the original rear outer panel, so that the new rear outer panel can be restored to the original rear outer panel structure after being cut along the cutting line.

[0022] Preferably, in the method for manufacturing a wedge-shaped low wind resistance cab, the rear outer panel has two states:

[0023] 1) The rear outer panel is not cut, with dimensions of 228×2390×1245, and is mounted on the wedge-shaped low wind resistance cab;

[0024] 2) The rear outer panel is cut to size 228×2190×1245 and is installed on the original platform cab.

[0025] Preferably, in the method for manufacturing a wedge-shaped low wind resistance cab, in the floor assembly:

[0026] The middle floor is manufactured using the original production platform;

[0027] The left and right sides of the floor are remanufactured and widened according to the positions of the corresponding side panel assemblies. Meanwhile, the new left and right sides of the floor can be restored to the original left and right sides of the floor structure after being cut along the cutting lines.

[0028] The rear floor was re-manufactured and widened according to the location of the corresponding side panel assembly;

[0029] The floor frame is manufactured using the original production platform;

[0030] The longitudinal beams and the middle cross beams of the framework are manufactured using the original production platform;

[0031] The left and right cross beams are widened according to the adjusted position of the side panel assembly.

[0032] Preferably, in the method for manufacturing a wedge-shaped low wind resistance cab, the left and right floors are provided with two states:

[0033] 1) The left and right floors are not cut, with dimensions of 1256×681×100, and are mounted on a wedge-shaped low wind resistance cab;

[0034] 2) The left and right floors are cut to size 1256×631×100 and are installed on the original platform cab.

[0035] Preferably, in the method for manufacturing a wedge-shaped low-drag cab, the drag coefficient of the wedge-shaped low-drag cab is controlled at 0.396cd.

[0036] Preferably, in the method for manufacturing a wedge-shaped low-drag cab, the connection method between the front panel assembly, the side panel assembly, the door assembly, and the remanufactured top cover assembly, the rear panel assembly and the floor assembly follows the connection method of the original basic vehicle model.

[0037] By means of the above scheme, the present invention has at least the following advantages:

[0038] The present invention solves the disadvantage of large wind resistance of the existing flat-head cab and realizes universalization, platformization, maximum use of parts and minimum investment.

[0039] The present invention aims to achieve low wind resistance with minimal investment, thereby reducing energy consumption and reducing costs.

[0040] The above description is only an overview of the technical solution of the present invention. In order to more clearly understand the technical means of the present invention and implement it according to the contents of the specification, the following is a detailed description of the preferred embodiments of the present invention in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments are briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without creative work.

[0042] Figure 1 is a structural diagram of a basic cab of the present invention;

[0043] Figure 2 It is a schematic diagram of the structure of the present invention;

[0044] Figure 3 yes Figure 2 Stereogram;

[0045] Figure 4 is a Cd value diagram of wind resistance analysis of the wedge-shaped cab of the present invention;

[0046] Figure 5 is a schematic diagram of a top cover assembly of the present invention;

[0047] Figure 6 is a schematic diagram of the middle top cover cutting line of the present invention;

[0048] Figure 7 It is a schematic diagram of the rear enclosure assembly structure of the present invention;

[0049] Figure 8 is a schematic diagram of a cutting line of a rear outer panel of the present invention;

[0050] Fig. 9 is a structural schematic diagram of the base plate assembly of the present invention;

[0051] Fig.10 is a schematic diagram of the left floor cutting line of the present invention;

[0052] Fig.11 is a graph showing the relationship between energy consumption and wind resistance coefficient of the present invention;

[0053] Fig.12 is a drag coefficient diagram under simulation analysis of the present invention;

[0054] Fig.13 It is a connection structure of the newly developed parts of the cab of the present invention and a universal connection structure diagram;

[0055] Fig.14 It is a top cover connection structure diagram of the present invention;

[0056] Fig.15 This is a diagram of the connection structure of the rear outer panel of the present invention;

[0057] Fig.16This is a diagram of the left floor connection structure of the present invention;

[0058] Fig.17 This is a cloud diagram of the bending stiffness analysis of the cab of the present invention;

[0059] Fig.18 It is a cloud diagram of the torsional stiffness analysis of the cab of the present invention.

[0060] In the figure:

[0061] 1 Front assembly 2 Side panel assembly 3 Door assembly 4 Top cover assembly 5 Rear assembly 6 Bottom plate assembly 41 Left top cover 42 Right top cover 43 Front cover 44 Rear top cover 45 Top cover frame 46 Left beam 47 Right beam 48 Middle top cover 51 Rear frame 52 Rear outer panel 61 Middle floor 62 Left floor 63 Right floor 64 Rear floor 65 Floor frame 66 Stringer A Basic cab B Cab DETAILED DESCRIPTION

[0062] In order to make the purpose, technical solution and advantages of the embodiments of the present application clearer, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, rather than all the embodiments. The components of the embodiments of the present application described and shown in the drawings here can be arranged and designed in various different configurations.

[0063] Therefore, the following detailed description of the embodiments of the present application provided in the accompanying drawings is not intended to limit the scope of the present application for which protection is sought, but merely represents selected embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in the field without creative work are within the scope of protection of the present application.

[0064] Example

[0065] like Figure 2 , Figure 3 , Figure 4 and Fig.11 As shown, a method for manufacturing a wedge-shaped low wind resistance cab comprises the following steps:

[0066] Using the original production platform, the front panel assembly 1, the side panel assembly 2 and the door assembly 3 of the cab are manufactured;

[0067] According to the structural requirements of the wedge-shaped low wind resistance cab, the corresponding top cover assembly 4, rear enclosure assembly 5 and bottom plate assembly 6 are manufactured;

[0068] The side panel assembly and the door assembly are rotated 3° around the A-pillar, and the corresponding front panel assembly, top cover assembly, rear panel assembly and bottom plate assembly are assembled to obtain a wedge-shaped low-wind-drag cab B.

[0069] like Figure 5 and Figure 6 As shown, the present invention is directed to the manufacture of a top cover assembly:

[0070] The left and right top covers 41 and 42 are rotated 3° along with the side panel assembly and are manufactured using the original production platform;

[0071] The front top cover 43 is manufactured using the original production platform. During installation, the front top cover is shaped and welded according to the side top cover.

[0072] The rear top cover 44 is newly developed and manufactured according to the positions of the left and right top covers;

[0073] The top cover frame 45 is manufactured using the original production platform, wherein the left and right cross beams 46 and 47 in the top cover frame that contact the left and right top covers are lengthened so as to contact the corresponding left and right top covers;

[0074] The middle top cover 48 is developed and manufactured on the basis of the original middle top cover, so that the new middle top cover can be restored to the original middle top cover structure after being cut along the cutting line.

[0075] Among them, the middle top cover has two states:

[0076] 1) The middle roof cover is not cut, with dimensions of 1410×1774×180, and is mounted on a wedge-shaped low wind resistance cab;

[0077] 2) The middle top cover is cut to size 1410×1574×180 and is installed on the original platform cab.

[0078] The width of the middle top cover in the above two states differs by 200mm; it is formed by a stamping die (universal die), but the trimming die is different, and the cutting position is as follows Figure 6 shown.

[0079] like Figure 7 As shown in FIG8 , the present invention is directed to the manufacture of a rear enclosure assembly:

[0080] The rear enclosure frame 51 is manufactured using the original production platform, and the joint between the rear enclosure frame and the side enclosure assembly is remanufactured according to the location of the side enclosure assembly;

[0081] The rear outer panel 52 is developed and manufactured based on the original rear outer panel, so that the new rear outer panel can be restored to the original rear outer panel structure after being cut along the cutting line.

[0082] The rear outer panel has two states:

[0083] 1) The rear outer panel is not cut, with dimensions of 228×2390×1245, and is mounted on the wedge-shaped low wind resistance cab;

[0084] 2) The rear outer panel is cut to size 228×2190×1245 and is installed on the original platform cab.

[0085] The width of the rear outer panel in the above two states differs by 200mm; the stamping mold is formed (universal mold), but the trimming mold is different, and the cutting position is as follows Figure 8 shown.

[0086] like Fig. 9 and Fig.11 As shown, the present invention is directed to the manufacture of the bottom plate assembly 6:

[0087] The middle floor 61 is manufactured using the original production platform;

[0088] The left and right floors 62 and 63 are remanufactured and widened according to the positions of the corresponding side panel assemblies. Meanwhile, the new left and right floors can be restored to the original left and right floor structures after being cut along the cutting lines.

[0089] The rear floor 64 is re-manufactured and widened according to the location of the corresponding side panel assembly;

[0090] The floor frame 65 is manufactured using the original production platform;

[0091] The longitudinal beam 66 and the middle cross beam of the framework are manufactured using the original production platform;

[0092] The left and right cross beams are widened according to the adjusted position of the side panel assembly.

[0093] The left and right floors have two states:

[0094] 1) The left and right floors are not cut, with dimensions of 1256×681×100, and are mounted on a wedge-shaped low wind resistance cab;

[0095] 2) The left and right floors are cut to size 1256×631×100 and are installed on the original platform cab.

[0096] The width of the left and right floors in the above two states differs by 50mm; they are formed by stamping molds (universal molds), but the trimming molds are different. Fig.10 shown.

[0097] The wind resistance coefficient of the wedge-shaped low wind resistance cab adopted in the present invention is controlled at 0.396cd.

[0098] The connection method among the front enclosure assembly, the side enclosure assembly, the door assembly, and the remanufactured top cover assembly, the rear enclosure assembly, and the bottom plate assembly of the present invention follows the connection method of the original basic vehicle model.

[0099] In the present invention, the original narrow-body cab A (width 2300mm) is widened to cab B (width 2500mm). While widening, the main focus is on reducing the wind resistance coefficient of the cab to achieve universal platformization of vehicle models.

[0100] Table 1

[0101]

[0102]

[0103] From the above table 1, we can clearly know the correlation between the various components of the basic cab A and the new cab B. By borrowing (using) and manufacturing the basic cab A through the cutting line during the new development, cost savings can be achieved. According to the above table 1, the commonality rate of the development plan of its low wind resistance platform is as high as: 75.8%, which greatly saves investment.

[0104] In this engine, the side of the cab is rotated 3° around the A-pillar to form a wedge shape, which effectively guides the airflow. The wedge-shaped cab is tested and optimized for wind resistance coefficient through CFD analysis and simulation. The model cab is used for wind tunnel tests, such as Fig.12 , verifying that the cab reaches the target drag coefficient of 0.42cd or less. The drag coefficient can also be further optimized by adding low-drag kits, such as fairings, underbody guards, door lower guards, side skirts, and cargo box rear spoilers, making the cab drag coefficient even lower.

[0105] Fig.13 The following are the connection structures and universal connections of the newly developed parts of the cab.

[0106] From the AA section (middle top cover connection structure):

[0107] like Fig.14 As shown, the connection structure between the wedge-shaped cab middle cover and the left and right side covers is obtained by cutting the middle cover at the cutting line to obtain the middle cover of the basic vehicle. The drawing and punching dies of the two models of the middle cover can be used universally, and only the final trimming dies are different, which can save development costs.

[0108] Section B (rear outer panel connection structure)

[0109] like Fig.15 As shown, the connection structure of the wedge-shaped cab rear panel and the left and right side panels is obtained by cutting the rear panel at the cutting line to obtain the rear panel of the base vehicle. The drawing and punching dies of the two models of the rear panel can be used universally, and only the final trimming die is different, which can save development costs.

[0110] CC section (left floor connection structure)

[0111] like Fig.16 As shown in the figure, the connection structure between the left and right floors of the wedge-shaped cab and the inner panel of the door sill is obtained by cutting the left and right floors at the cutting line to obtain the left and right floors of the basic vehicle. The drawing and punching dies of the left and right floors of the two models can be used in common, and only the final trimming dies are different, which can save development costs.

[0112] Wedge-shaped cab body-in-white performance:

[0113] The cab body-in-white stiffness is an important parameter that affects the performance of the vehicle body and directly reflects the vehicle's ability to withstand load impact. The higher the body-in-white torsional stiffness and bending stiffness, the more beneficial it is to NVH-related performance.

[0114] By comparing the bending stiffness and torsional stiffness parameters of the wedge-shaped cab with those of the base vehicle, it is determined whether the wedge-shaped cab meets the requirements.

[0115] CAE analysis of cab stiffness, such as Fig.17 and Fig.18 shown.

[0116] The analysis results are shown in Table 2.

[0117] Table 2

[0118]

[0119] The longitudinal beam of the wedge-shaped cab floor is consistent with that of the basic vehicle, so the bending stiffness is equivalent to that of the basic vehicle; the wedge-shaped cab body is wider and the torsional cross-section is larger, so the torsional stiffness is slightly better than that of the basic vehicle, so the performance of the wedge-shaped cab white body meets the requirements.

[0120] The present invention has:

[0121] (1) Low wind resistance: The wedge-shaped cab is wider than the traditional sliding cab, and the wind resistance coefficient is improved by 12%. Through exterior decoration and other low wind resistance kits, the wind resistance coefficient of the whole vehicle is controlled below 0.42, greatly reducing energy consumption;

[0122] (2) Universal platform: The vehicle body is innovatively widened by rotating the side panels to achieve maximum universality. The mold investment is reduced by 75% compared to the investment in newly developed body-in-white molds, and the investment in interior and exterior molds is reduced by 50%, saving more than 60% in total investment costs.

[0123] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, further definition and explanation thereof is not required in subsequent drawings.

[0124] In the description of this application, it should be noted that the terms "vertical", "horizontal", "inside", "outside", etc. indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, or the positions or positional relationships in which the product of the application is usually placed when in use. They 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, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on this application. In addition, the terms "first", "second", etc. are only used to distinguish the description, and cannot be understood as indicating or implying relative importance.

[0125] In addition, the terms "horizontal", "vertical" and the like do not mean that the components are required to be absolutely horizontal or vertical, but can be slightly tilted. For example, "horizontal" only means that its direction is more horizontal than "vertical", and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0126] In the description of this application, it should also be noted that, unless otherwise clearly specified and limited, the terms "set", "install", "connect", and "connect" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two elements. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0127] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. It should be pointed out that a person skilled in the art can make several improvements and modifications without departing from the technical principles of the present invention, and these improvements and modifications should also be regarded as within the scope of protection of the present invention.

Claims

1. A method for manufacturing a wedge-shaped low wind resistance cab, characterized in that: The following steps are involved: Using the original production platform, the cab's front panel assembly, side panel assembly and door assembly are manufactured; According to the structural requirements of the wedge-shaped low wind resistance cab, the corresponding top cover assembly, rear enclosure assembly and bottom plate assembly are manufactured; The side panel assembly and the door assembly are rotated 3° around the A-pillar, and the corresponding front panel assembly, top cover assembly, rear panel assembly and bottom panel assembly are assembled to obtain a wedge-shaped low-wind-drag cab.

2. The method for manufacturing a wedge-shaped low wind resistance cab according to claim 1, characterized in that: In the top cover assembly: The left and right top covers are rotated 3° along with the side panel assembly and are manufactured using the original production platform; The front roof is manufactured on the original production platform. During installation, the front roof is shaped and welded according to the side roof. The rear top cover is redeveloped and manufactured according to the positions of the left and right top covers; The top cover frame is manufactured using the original production platform, wherein the left and right cross beams in the top cover frame that contact the left and right top covers are lengthened so as to contact the corresponding left and right top covers; The middle top cover is developed and manufactured based on the original middle top cover, so that the new middle top cover can be restored to the original middle top cover structure after being cut along the cutting line.

3. The method for manufacturing a wedge-shaped low wind resistance cab according to claim 2, characterized in that: The middle top cover has two states: 1) The middle roof cover is not cut, with dimensions of 1410×1774×180, and is mounted on a wedge-shaped low wind resistance cab; 2) The middle top cover is cut to size 1410×1574×180 and is installed on the original platform cab.

4. The method for manufacturing a wedge-shaped low wind resistance cab according to claim 1, characterized in that: In the rear enclosure assembly: The rear panel frame is manufactured using the original production platform, and the joint between the rear panel frame and the side panel assembly is re-manufactured according to the location of the side panel assembly; The rear outer panel is developed and manufactured based on the original rear outer panel, so that the new rear outer panel can be restored to the original rear outer panel structure after being cut along the cutting line.

5. The method for manufacturing a wedge-shaped low wind resistance cab according to claim 4, characterized in that: The rear outer panel has two states: 1) The rear outer panel is not cut, with dimensions of 228×2390×1245, and is mounted on the wedge-shaped low wind resistance cab; 2) The rear outer panel is cut to size 228×2190×1245 and is installed on the original platform cab.

6. The method for manufacturing a wedge-shaped low wind resistance cab according to claim 1, characterized in that: In the base plate assembly: The middle floor is manufactured using the original production platform; The left and right sides of the floor are remanufactured and widened according to the positions of the corresponding side panel assemblies. Meanwhile, the new left and right sides of the floor can be restored to the original left and right sides of the floor structure after being cut along the cutting lines. The rear floor was re-manufactured and widened according to the location of the corresponding side panel assembly; The floor frame is manufactured using the original production platform; The longitudinal beams and the middle cross beams of the framework are manufactured using the original production platform; The left and right cross beams are widened according to the adjusted position of the side panel assembly.

7. The method for manufacturing a wedge-shaped low wind resistance cab according to claim 6, characterized in that: The left and right floors have two states: 1) The left and right floors are not cut, with dimensions of 1256×681×100, and are mounted on a wedge-shaped low wind resistance cab; 2) The left and right floors are cut to size 1256×631×100 and are installed on the original platform cab.

8. A method for manufacturing a wedge-shaped low wind resistance cab according to any one of claims 1 to 7, characterized in that: The drag coefficient of the wedge-shaped low-drag cab is controlled at 0.396cd.

9. A method for manufacturing a wedge-shaped low wind resistance cab according to any one of claims 1 to 7, characterized in that: The connection method between the front panel assembly, side panel assembly, door assembly and the remanufactured top cover assembly, rear panel assembly and floor assembly follows the connection method of the original basic model.

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