Steel-aluminum mixed rear anti-collision beam structure, manufacturing method thereof and vehicle

Abstract

The invention discloses a steel-aluminum mixed rear anti-collision beam structure, a manufacturing method thereof and a vehicle. The structure is composed of a rear anti-collision beam, a left rear energy absorption box, a right rear energy absorption box and a traction ring connecting sleeve. The rear anti-collision beam is a tubular beam made of a high-strength steel plate, has a rectangular cross section, is welded into a straight pipe through high frequency, and is formed through a pipe bending process. The left rear energy absorption box and the right rear energy absorption box are connected with the rear anti-collision beam into a whole through the semi-solid tubular beam aluminum casting technology, X-shaped reinforcing ribs are arranged in the energy absorption boxes, and the energy absorption effect is improved. And the traction ring connecting sleeve is connected with the rear anti-collision beam through a welding process. According to the structure, the strength and rigidity of the rear anti-collision beam are improved, the weight is reduced, the cost is reduced, and good application prospects are achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile parts, and in particular to a steel-aluminum hybrid rear anti-collision beam structure and a manufacturing method thereof, and a vehicle. Background Art

[0002] The rear anti-collision beam assembly of a car is an important safety component installed at the rear of the car body. Its main function is to absorb collision energy in the event of a low-speed collision and reduce damage to the car body; in the event of a high-speed collision, it avoids damage to the battery pack or fuel tank, thereby protecting the safety of the passengers in the car.

[0003] At present, automobile rear anti-collision beam assemblies can be divided into steel rear anti-collision beams and aluminum rear anti-collision beams according to materials. Among steel anti-collision beams, anti-collision cross beams and energy absorption boxes usually adopt steel plate stamping and welding structures. This structure has the following problems: 1. There are a large number of welding points in the structure, which increases the welding process; 2. The welding edges and welding points of multiple stamping parts increase the weight; 3. The manufacturing cost is high.

[0004] Although the aluminum rear anti-collision beam is light in weight, the unit cost is high and there may be deficiencies in collision performance.

[0005] Therefore, there is an urgent need for a new rear anti-collision beam structure that can not only ensure collision safety performance but also achieve the goals of lightweight and cost optimization. Summary of the invention

[0006] The purpose of the present invention is to overcome the deficiencies of the prior art and provide a steel-aluminum hybrid rear anti-collision beam structure and a manufacturing method and a vehicle, so as to improve the structural strength and rigidity of the anti-collision beam, reduce the welding process, and reduce the vehicle body weight and production cost.

[0007] To achieve the above-mentioned purpose, in the first aspect, the present invention provides a steel-aluminum hybrid rear anti-collision beam structure, including: a rear anti-collision beam made of high-strength steel plate, and an energy absorption box is provided at both ends of the rear anti-collision beam; the energy absorption box is connected to the rear anti-collision beam into a whole by a semi-solid aluminum casting process; the energy absorption box is connected to the longitudinal beam assembly through an energy absorption box mounting plate.

[0008] In some optional embodiments of the present invention, the energy absorption box includes a accommodating cavity which is connected to the rear anti-collision beam as a whole and is open at both ends, and an energy absorption cavity which is connected to the outer wall of the accommodating cavity at one end, and the other end of the energy absorption cavity is connected to the energy absorption box mounting plate.

[0009] Preferably, a plurality of "X"-shaped reinforcing ribs are provided in the energy absorbing cavity to improve the energy absorbing effect during a collision.

[0010] Further preferably, the plurality of "X"-shaped reinforcing ribs are arranged along the length direction of the energy absorbing cavity.

[0011] In some optional embodiments of the present invention, the energy absorption box mounting plate is integrally formed with the energy absorption box.

[0012] Preferably, the energy absorption box mounting plate is provided with a cylindrical pin for mounting and positioning with the longitudinal beam assembly; the energy absorption box mounting plate is provided with a mounting hole for bolt connection with the longitudinal beam assembly.

[0013] In some optional embodiments of the present invention, in some optional embodiments of the present invention, a prefabricated through hole is provided on the rear anti-collision beam; the towing ring connecting sleeve is connected to the rear anti-collision beam through the prefabricated through hole for installing a trailer hook.

[0014] In a second aspect, the present invention provides a method for manufacturing a steel-aluminum hybrid rear anti-collision beam structure, which is used to manufacture the steel-aluminum hybrid rear anti-collision beam structure described in the first aspect, and the method comprises the following steps:

[0015] The high-strength steel plates are welded at high frequency into a rectangular straight tube beam, and the rear anti-collision beam is formed by a tube bending process;

[0016] The rear anti-collision beam is placed in the preheated mold cavity, and the semi-solid aluminum alloy heated to the semi-solid temperature range is injected into the mold cavity by using the semi-solid aluminum casting process, and the energy absorption box and the energy absorption box mounting plate are integrally formed, and the energy absorption box and the rear anti-collision beam are cast into one piece;

[0017] In some optional embodiments of the present invention, the mold is preheated to 220-240° C. before the rear anti-collision beam is placed therein.

[0018] In some optional embodiments of the present invention, the aluminum alloy is heated to a semi-solid temperature range of 570-590° C. and injected into the mold cavity at a speed of 3-4 m / s and a pressure of 70-80 MPa.

[0019] In some optional embodiments of the present invention, after injecting the semi-solid aluminum alloy into the mold cavity:

[0020] Increase the pressure to 160-180 MPa;

[0021] Control the temperature between 630 and 650°C;

[0022] Keep heat and pressure for more than 2 seconds.

[0023] In some optional embodiments of the present invention, the parts are cooled to the mold temperature through a water channel in the mold; and the parts are taken out of the mold cavity and cooled at room temperature.

[0024] In a third aspect, the present invention provides a vehicle, comprising the steel-aluminum hybrid rear anti-collision beam structure as described in the first aspect.

[0025] The present invention provides a steel-aluminum hybrid rear anti-collision beam structure and a manufacturing method thereof, and a vehicle, which have the following beneficial effects:

[0026] 1. The rear anti-collision beam of the present invention adopts a rectangular closed cross-section. Compared with the traditional steel plate welded structure, the structural strength of the rear anti-collision beam is significantly increased, the deformation of the anti-collision beam crossbeam during collision can be effectively reduced, and the safety of the vehicle is improved.

[0027] 2. The left and right rear energy absorption boxes are connected to the rear anti-collision beam through the semi-solid tubular beam cast aluminum process, which enhances the strength and rigidity of the connection. The "X"-shaped reinforcement ribs on the energy absorption box are conducive to the energy absorption box's collapse and energy absorption during a collision.

[0028] 3. The left and right rear energy absorption boxes are manufactured by semi-solid aluminum casting process, which eliminates the traditional steel plate stamping and welding energy absorption box inner and outer plates, and integrates the energy absorption box mounting plate into one, reducing the welding process and the number of welding points, and effectively reducing the manufacturing cost.

[0029] 4. Through the application of steel-aluminum hybrid structure design and semi-solid aluminum casting process, the overall weight is optimized while ensuring performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] In order to more clearly illustrate the technical solutions of the embodiments disclosed in the present invention, the drawings of the embodiments will be briefly introduced below. These drawings are only used for illustrative purposes and are not intended to limit the protection scope of the present invention.

[0031] Figure 1 This is a schematic diagram of the structural composition of a steel-aluminum hybrid rear anti-collision beam provided by an embodiment of the present invention;

[0032] Figure 2 It is a front schematic diagram of a steel-aluminum hybrid rear anti-collision beam structure provided by an embodiment of the present invention;

[0033] Figure 3 Figure 2 Schematic diagram of the middle AA section;

[0034] Figure 4 Figure 2 Schematic diagram of the middle BB section;

[0035] Figure 5 Schematic diagram of a rear anti-collision beam of a steel-aluminum hybrid rear anti-collision beam structure provided by an embodiment of the present invention;

[0036] Figure 6 Schematic diagram of an energy absorption box of a steel-aluminum hybrid rear anti-collision beam structure provided by an embodiment of the present invention;

[0037] In the figure: rear anti-collision beam 1; left energy absorption box 2; right energy absorption box 3; traction ring connecting sleeve 4; left energy absorption box mounting plate 5; right energy absorption box mounting plate 6; accommodating cavity 7; energy absorption cavity 8; "X"-shaped reinforcing rib 9; traction ring connecting sleeve mounting hole 10; cylindrical pin 11; bolt through hole 12. DETAILED DESCRIPTION

[0038] The technical solution of the present invention (including the preferred technical solution) is further described in detail below by means of the accompanying drawings and by listing some optional embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0039] Example 1

[0040] like Figures 1 to 6 As shown, this embodiment provides a steel-aluminum hybrid rear anti-collision beam structure, including a rear anti-collision beam 1, a left rear energy absorption box 2, a right energy absorption box 3, a traction ring connecting sleeve 4, a left energy absorption box mounting plate 5, and a right energy absorption box mounting plate 6.

[0041] The rear anti-collision beam 1 is made of high-strength steel plate through high-frequency welding process to form a rectangular straight tube beam with a wall thickness of 1.8mm. The steel plate material is high-strength steel with a tensile strength of not less than 780MPa. The straight tube beam is bent into shape through a tube bending process to form an arc structure that meets the rear end layout requirements of the vehicle model. A traction ring connecting sleeve installation hole 10 is opened at an appropriate position of the rear anti-collision beam 1 for installing the traction ring connecting sleeve 4.

[0042] The left energy absorption box 2 and the right energy absorption box 3 have the same structure, both of which are made of aluminum alloy, and are integrated with the rear anti-collision beam 1 through a semi-solid casting process. Each energy absorption box includes two main parts: one is a receiving cavity 7 connected to the rear anti-collision beam 1 and opened at both ends, which is used for the rear anti-collision beam 1 to pass through and accommodate and fix the rear anti-collision beam 1; the other is an energy absorption cavity 8 connected to the outer wall of the receiving cavity 7, which is used to absorb collision energy. This integrated design improves the strength and rigidity of the connection between the rear anti-collision beam and the energy absorption box, and effectively absorbs collision energy.

[0043] The left energy absorption box mounting plate 5 and the right energy absorption box mounting plate 6 are both made of aluminum alloy; the left energy absorption box mounting plate 5 is integrally formed with the left energy absorption box 2 when the left energy absorption box 2 is formed, and the right energy absorption box mounting plate 6 is integrally formed with the right energy absorption box 3 when the right energy absorption box 3 is formed. A cylindrical pin 11 is riveted on each energy absorption box mounting plate, which is used for accurate installation and positioning with the left and right rear longitudinal beam assemblies, respectively. Each energy absorption box mounting plate is also provided with three bolt through holes 12, which are used to fix the rear anti-collision beam assembly to the rear longitudinal beam assembly of the vehicle body by bolts to ensure assembly accuracy.

[0044] The towing ring connecting sleeve 4 is fixed to the rear anti-collision beam 1 through a welding process and is used to install a trailer hook to meet the vehicle towing requirements.

[0045] Example 2

[0046] On the basis of Example 1, the structure of the energy absorption box is optimized to improve the energy absorption effect.

[0047] Energy absorption box structure optimization: the energy absorption boxes 2 and 3 include a receiving chamber 7 connected to the rear anti-collision beam 1, and an energy absorption chamber 8 connected to the outer wall of the receiving chamber 7.

[0048] A plurality of “X”-shaped reinforcing ribs 9 are provided in the energy absorbing cavity 8 to improve the energy absorbing effect during a collision.

[0049] In some embodiments of the present invention, three “X”-shaped reinforcing ribs 9 are arranged along the length direction of the energy absorbing cavity 8 .

[0050] Example 3

[0051] This embodiment provides a method for manufacturing a steel-aluminum hybrid rear anti-collision beam structure, which is used to manufacture the steel-aluminum hybrid rear anti-collision beam structure in Embodiment 1 and Embodiment 2, and the method comprises the following steps:

[0052] 1. Manufacturing of rear anti-collision beam 1:

[0053] High-strength steel plates are selected and welded into rectangular closed straight tube beams using high-frequency welding technology.

[0054] Through the tube bending process, the straight tube beam is bent into shape according to the design requirements to ensure that its shape fits the spatial layout of the rear of the vehicle.

[0055] A traction ring connecting sleeve installation hole 10 is reserved on the rear anti-collision beam 1 for installing the traction ring connecting sleeve 4 .

[0056] 2. Manufacturing and connection of energy absorption box and energy absorption box mounting plate:

[0057] Mold preheating: Preheat the semi-solid aluminum casting mold to 220-240°C to ensure stable temperature during the casting process.

[0058] Placing the rear anti-collision beam 1: placing the formed rear anti-collision beam 1 into the preheated mold cavity and positioning it accurately.

[0059] Heating and injection of aluminum alloy:

[0060] Heat the aluminum alloy to 570-590°C to reach the semi-solid temperature range.

[0061] The semi-solid aluminum alloy is injected into the mold cavity at a speed of 3 to 4 m / s and a pressure of 70 to 80 MPa.

[0062] After the aluminum alloy fills the cavity, the pressure is increased to 160-180 MPa, the temperature is controlled between 630-650°C, and the temperature and pressure are maintained for more than 2 seconds to ensure that the aluminum alloy is firmly combined with the rear bumper beam 1 without pores and shrinkage.

[0063] Cooling and removal:

[0064] The casting is cooled to the mold temperature through the water channel in the mold, and the cooling time is about 30 seconds.

[0065] Open the mold, take out the energy absorption box, energy absorption box mounting plate, and rear anti-collision beam that have been connected into a whole, and cool them at room temperature.

[0066] In some embodiments of the present invention, the towing ring connecting sleeve 4 is inserted into the mounting hole 10 reserved in the rear anti-collision beam 1 and fixed by a welding process.

[0067] Example 4

[0068] This embodiment provides a method for manufacturing a steel-aluminum hybrid rear anti-collision beam structure, which is used to manufacture the steel-aluminum hybrid rear anti-collision beam structure in Embodiment 1 and Embodiment 2, and the method comprises the following steps:

[0069] 1. Manufacturing of rear anti-collision beam:

[0070] (1) Cut the high-strength steel plate into the required size and form it by roll forming.

[0071] (2) High-frequency welding is used to form a closed cross section.

[0072] (3) Forming it into the desired shape through the pipe bending process.

[0073] (4) Grind the weld and surface.

[0074] (5) Degreasing and rust removal of the surface.

[0075] (6) Spray high temperature resistant anti-stick coating.

[0076] 2. Semi-solid casting process:

[0077] (1) Preheat the mold to 220-240°C.

[0078] (2) Heat the AlSi7Mg alloy to 570-590°C.

[0079] (3) Place the rear anti-collision beam into the mold cavity.

[0080] (4) Inject the semi-solid alloy at a speed of 3 to 4 m / s.

[0081] (5) Increase the pressure to 160-180 MPa.

[0082] (6) Control the temperature between 630 and 650°C.

[0083] (7) Maintain pressure for more than 3 seconds.

[0084] (8) Cooling through water channels.

[0085] (9) Demolding and post-processing.

[0086] 3. Assembly process:

[0087] (1) Weld the traction ring connecting sleeve into place.

[0088] (2) Press the cylindrical pin onto the energy absorption box mounting plate.

[0089] (3) Carry out dimensional inspection and strength test on the whole.

[0090] Example 5

[0091] This embodiment provides a vehicle installation method using the above steel-aluminum hybrid rear anti-collision beam structure, and the specific steps are as follows:

[0092] 1) Preliminary installation: In the welding workshop, the rear anti-collision beam assembly is pre-positioned on the body in white by riveting the positioning cylindrical pins 6 on the left and right energy absorption boxes 2 and 3.

[0093] 2) Fixed connection: Use 3 M8 bolts on each side to firmly connect the rear anti-collision beam assembly to the rear longitudinal beam sheet metal to ensure the accurate installation position.

[0094] 3) Painting treatment: The installed rear anti-collision beam assembly is sent to the painting workshop together with the vehicle body for electrophoretic painting to improve the corrosion resistance of the rear anti-collision beam assembly and extend its service life.

[0095] 4) Assembly completed: After painting, the rear bumper beam assembly is subjected to a final inspection to ensure that it is securely installed, accurately positioned, and that there is no looseness in any connection.

[0096] Example 6

[0097] This embodiment provides a vehicle using the above steel-aluminum hybrid rear anti-collision beam structure. The vehicle can be a traditional fuel vehicle or a new energy vehicle.

[0098] The present invention adopts a steel-aluminum hybrid structure and combines the semi-solid tube beam aluminum casting process to give full play to the advantages of steel and aluminum alloy materials, which not only improves the structural strength and rigidity of the rear anti-collision beam, but also achieves lightweight and reduces production costs. At the same time, it reduces welding procedures, improves production efficiency, and has good economic and social benefits.

[0099] Those skilled in the art will readily appreciate that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, combinations, replacements, improvements, etc. made within the spirit and principles of the present invention are included within the protection scope of the present invention.

Claims

1. A steel-aluminum hybrid rear anti-collision beam structure, characterized in that: include: The rear anti-collision beam is made of high-strength steel plate, and an energy absorption box is provided at both ends of the rear anti-collision beam; The energy absorption box is connected to the rear anti-collision beam as a whole by using a semi-solid aluminum casting process; the energy absorption box is connected to the longitudinal beam assembly through an energy absorption box mounting plate.

2. The steel-aluminum hybrid rear anti-collision beam structure according to claim 1 is characterized by: The energy absorption box includes a receiving cavity connected to the rear anti-collision beam as a whole and opened at both ends, and an energy absorption cavity with one end connected to the outer wall of the receiving cavity as a whole, and the other end of the energy absorption cavity is connected to the energy absorption box mounting plate.

3. The steel-aluminum hybrid rear anti-collision beam structure according to claim 2 is characterized by: A plurality of "X"-shaped reinforcing ribs are arranged in the energy absorbing cavity to improve the energy absorbing effect during a collision; the plurality of "X"-shaped reinforcing ribs are arranged along the length direction of the energy absorbing cavity.

4. The steel-aluminum hybrid rear anti-collision beam structure according to claim 1 is characterized by: The energy absorption box mounting plate is integrally formed with the energy absorption box; a cylindrical pin is provided on the energy absorption box mounting plate for mounting and positioning with the longitudinal beam assembly; a mounting hole is provided on the energy absorption box mounting plate for bolt connection with the longitudinal beam assembly.

5. The steel-aluminum hybrid rear anti-collision beam structure according to claim 1 is characterized by: In some optional embodiments of the present invention, a prefabricated through hole is provided on the rear anti-collision beam; the towing ring connecting sleeve is connected to the rear anti-collision beam through the prefabricated through hole for installing a trailer hook.

6. A method for manufacturing a steel-aluminum hybrid rear anti-collision beam structure, used to manufacture the steel-aluminum hybrid rear anti-collision beam structure as claimed in any one of claims 1 to 5, characterized in that: The method comprises the following steps: The high-strength steel plates are welded at high frequency into a rectangular straight tube beam, and the rear anti-collision beam is formed by a tube bending process; The rear anti-collision beam is placed in the preheated mold cavity, and the semi-solid aluminum alloy heated to the semi-solid temperature range is injected into the mold cavity using the semi-solid aluminum casting process. The energy absorbing box and the energy absorbing box mounting plate are integrally formed while the energy absorbing box and the rear anti-collision beam are cast as one piece.

7. The method for manufacturing a steel-aluminum hybrid rear anti-collision beam structure according to claim 6, characterized in that: Before placing the rear anti-collision beam, preheat the mold to 220-240°C; heat the aluminum alloy to a semi-solid temperature range of 570-590°C, and inject it into the mold cavity at a speed of 3-4m / s and a pressure of 70-80MPa.

8. The method for manufacturing a steel-aluminum hybrid rear anti-collision beam structure according to claim 7, characterized in that: After the semi-solid aluminum alloy is injected into the mold cavity: Increase the pressure to 160-180 MPa; Control the temperature between 630 and 650°C; Keep heat and pressure for more than 2 seconds.

9. The method for manufacturing a steel-aluminum hybrid rear anti-collision beam structure according to any one of claims 6 to 8, characterized in that: The parts are cooled to the mold temperature through the water channel in the mold; the parts are taken out of the mold cavity and cooled at room temperature.

10. A vehicle comprising the steel-aluminum hybrid rear anti-collision beam structure as claimed in any one of claims 1 to 5.

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