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

Abstract

The invention discloses a steel and aluminum mixed front anti-collision beam structure, a manufacturing method thereof and a vehicle, the steel and aluminum mixed front anti-collision beam structure comprises a front anti-collision beam made of a high-strength steel plate and energy absorption boxes arranged at the two ends of the front anti-collision beam, and the energy absorption boxes are connected with the front anti-collision beam into a whole through a semi-solid aluminum casting technology. The energy absorption box comprises a containing cavity connected with the front anti-collision beam and an energy absorption cavity, the energy absorption cavity is divided into a plurality of cavities through criss-cross partition plates, and the energy absorption effect is improved. A steel-aluminum mixed structure is adopted, a semi-solid casting process is combined, the structural strength is guaranteed, light weight is achieved, meanwhile, the production cost is reduced, and the production efficiency is improved.

Description

Technical Field

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

[0002] The front anti-collision beam of a car is an important safety component located at the front of the car. Its main function is to reduce damage and protect the safety of passengers when the vehicle collides. There are two main types of existing front anti-collision beam assemblies:

[0003] The first is the traditional steel front bumper beam, whose cross beam is usually made of rolled parts or stamped parts, and the energy absorption box is made of steel plate stamping and welding structure. This structure has the following problems: 1) It requires a large number of welding points, 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] The second is an aluminum front bumper beam, which is lightweight but has the problem of high cost and relatively low strength and rigidity.

[0005] Therefore, there is an urgent need to develop a new front bumper beam structure that can not only improve the structural strength and rigidity of the front bumper beam, but also reduce the weight and cost of the front bumper beam structure, while having a reasonable manufacturing cost. Summary of the invention

[0006] The purpose of the present invention is to provide a steel-aluminum hybrid front anti-collision beam structure and its manufacturing method and vehicle to solve the above problems existing in the prior art. The structure combines the advantages of high-strength steel and aluminum alloy materials, adopts semi-solid casting technology, and achieves the goals of high strength, light weight and low cost.

[0007] To achieve the above-mentioned purpose, in the first aspect, the present invention provides a steel-aluminum hybrid front bumper beam structure, including: a front bumper beam made of high-strength steel plate, with an energy absorption box provided at both ends of the front bumper beam; the energy absorption box is connected to the front bumper 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 front 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, the cross-section of the energy absorption cavity is rectangular, and the energy absorption cavity is divided into multiple chambers by criss-crossing partitions; the center lines of the multiple chambers are parallel, and the center lines of the multiple chambers are perpendicular to the accommodating cavity.

[0010] Further preferably, the energy absorbing cavity is divided into a first cavity and a second cavity along the centerline direction of the accommodating cavity by a first partition, and the cross-sectional area of ​​the second cavity is larger than the cross-sectional area of ​​the second cavity.

[0011] Still further preferably, a plurality of second partitions perpendicular to the first partition are further provided in the first chamber.

[0012] Still further preferably, a plurality of third partitions perpendicular to the first partitions are further provided in the second chamber.

[0013] In some optional embodiments of the present invention, the energy absorption box mounting plate is welded to the end of 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 bolting with the longitudinal beam assembly.

[0014] In some optional embodiments of the present invention, a prefabricated through hole is provided on the front anti-collision beam; the front towing ring connecting sleeve is connected to the front anti-collision beam through the prefabricated through hole for installing a trailer hook.

[0015] In some optional embodiments of the present invention, rivet nuts are riveted on the front anti-collision beam for installing a front headlight bracket, a front bumper bracket, and an engine hood lock support bracket.

[0016] In a second aspect, the present invention provides a method for manufacturing a steel-aluminum hybrid front anti-collision beam structure, which is used to manufacture the steel-aluminum hybrid front anti-collision beam structure described in the first aspect, and the method comprises the following steps:

[0017] The high-strength steel plates are welded at high frequency into a rectangular straight tube beam, and the front anti-collision beam is formed by a tube bending process;

[0018] The front 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 is formed while the energy absorption box and the front anti-collision beam are cast into one body;

[0019] The energy absorption box mounting plate is connected to the energy absorption box through welding process to complete the installation of the energy absorption box mounting plate.

[0020] In some optional embodiments of the present invention, the front traction ring connecting sleeve is first connected to the front anti-collision beam through a welding process, and then the front anti-collision beam is placed in a preheated mold cavity.

[0021] In some optional embodiments of the present invention, the mold is preheated to 220-240° C. before the front anti-collision beam is placed therein.

[0022] 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.

[0023] In some optional embodiments of the present invention, after injecting the semi-solid aluminum alloy into the mold cavity:

[0024] Increase the pressure to 160-180 MPa;

[0025] Control the temperature between 630 and 650°C;

[0026] Keep heat and pressure for more than 2 seconds.

[0027] 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.

[0028] In a third aspect, the present invention provides a vehicle, comprising the steel-aluminum hybrid front anti-collision beam structure as described in the first aspect.

[0029] The present invention provides a steel-aluminum hybrid front anti-collision beam structure and a manufacturing method thereof, and a vehicle, which have the following beneficial effects:

[0030] 1. High structural strength and good safety: The front anti-collision beam is made of high-strength steel plate and has a closed rectangular cross-section. Compared with the traditional steel plate welding structure, it significantly improves the structural strength and rigidity of the front anti-collision beam and enhances the safety performance of the vehicle during a collision.

[0031] 2. Lightweight design to reduce weight: The energy absorption box adopts semi-solid aluminum casting technology and is connected to the front anti-collision beam as a whole, making full use of the lightweight and high-strength characteristics of aluminum alloy materials, realizing the lightweight of the whole vehicle and reducing the overall weight of the vehicle.

[0032] 3. Simplified process and reduced cost: Through the semi-solid aluminum casting process, the energy absorption box and the front anti-collision beam are formed into one piece, eliminating the traditional steel plate stamping and welding structure, reducing the welding process, reducing production costs and improving production efficiency.

[0033] 4. Easy assembly and accurate positioning: The energy absorption box is connected to the longitudinal beam assembly through the energy absorption box mounting plate. The energy absorption box mounting plate is provided with cylindrical pins and mounting holes, which are convenient for installation and positioning with the vehicle body, simplifying the assembly process and improving the assembly accuracy.

[0034] 5. Good anti-corrosion performance and long service life: The front anti-collision beam can be electrophoretically coated in the paint shop, which increases the anti-corrosion performance, extends the service life of the components, and reduces the cost of maintenance and replacement.

[0035] 6. In line with industry trends and widely used: The structure achieves the goals of high strength, light weight and low cost, conforms to the development trend of the automotive industry and has broad application prospects. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] 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.

[0037] Figure 1 This is a schematic diagram of the structural composition of a steel-aluminum hybrid front anti-collision beam provided by an embodiment of the present invention;

[0038] Figure 2 It is a front schematic diagram of a steel-aluminum hybrid front anti-collision beam structure provided by an embodiment of the present invention;

[0039] Figure 3 yes Figure 2 Schematic diagram of the middle AA section;

[0040] Figure 4 Schematic diagram of a front anti-collision beam of a steel-aluminum hybrid front anti-collision beam structure provided by an embodiment of the present invention;

[0041] Figure 5 Schematic diagram of an energy absorption box of a steel-aluminum hybrid front anti-collision beam structure provided by an embodiment of the present invention;

[0042] Figure 6 It is a schematic diagram of an energy absorption box mounting plate of a steel-aluminum hybrid front anti-collision beam structure provided by an embodiment of the present invention;

[0043] In the figure: front anti-collision beam 1; left energy absorption box 2; right energy absorption box 3; left energy absorption box mounting plate 4; right energy absorption box mounting plate 5; front traction ring connecting sleeve 6; accommodating cavity 7; energy absorption cavity 8; first partition plate 9; second partition plate 10; third partition plate 11; rivet nut 12; front traction ring connecting sleeve mounting hole 13; cylindrical pin 14; bolt through hole 15. DETAILED DESCRIPTION

[0044] 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.

[0045] Example 1

[0046] like Figures 1 to 6As shown, this embodiment provides a steel-aluminum hybrid front anti-collision beam structure, including a front anti-collision beam 1, a left energy absorption box 2, a right energy absorption box 3, a left energy absorption box mounting plate 4, a right energy absorption box mounting plate 5, and a front traction ring connecting sleeve 6.

[0047] The front 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 front end layout requirements of the vehicle model. The front anti-collision beam 1 is provided with a plurality of rivet nut mounting holes for installing M8 rivet nuts 12, which are used to connect accessories such as the front headlight bracket, the front bumper bracket and the engine hood lock support bracket. In addition, a front towing ring connecting sleeve mounting hole 13 is opened at an appropriate position of the front anti-collision beam 1 for installing the front towing ring connecting sleeve 6.

[0048] 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 front anti-collision beam 1 through a semi-solid casting process. Each energy absorption box includes two main parts: one is a receiving chamber 7 connected to the front anti-collision beam 1 and opened at both ends, which is used for the front anti-collision beam 1 to pass through and accommodate and fix the front anti-collision beam 1; the other is an energy absorption chamber 8 connected to the outer wall of the receiving chamber 7, which is used to absorb collision energy. This integrated design improves the strength and rigidity of the connection between the front anti-collision beam and the energy absorption box, and effectively absorbs collision energy.

[0049] The left energy absorption box mounting plate 4 and the right energy absorption box mounting plate 5 are both made of aluminum alloy. The left energy absorption box mounting plate 4 is connected to the left energy absorption box 2 by welding, and the right energy absorption box mounting plate 5 is connected to the right energy absorption box 5 by welding. A cylindrical pin 14 is riveted on each energy absorption box mounting plate, which is used for accurate installation and positioning with the left and right front longitudinal beam assemblies, respectively. Each energy absorption box mounting plate is also provided with three bolt through holes 15, which are used to fix the front anti-collision beam assembly to the front longitudinal beam assembly of the vehicle body by bolts to ensure assembly accuracy.

[0050] In some optional embodiments of the present invention, a through hole is provided on one of the accommodating cavities 7 for passing the front towing ring connecting sleeve 6; the front towing ring connecting sleeve 6 is fixed to the front anti-collision beam 1 by a welding process and is used for installing a trailer hook to meet the vehicle towing requirements.

[0051] Example 2

[0052] On the basis of Example 1, the structure of the energy absorption box is optimized to improve the energy absorption effect.

[0053] Energy absorption box structure optimization: the energy absorption boxes 2 and 3 include a receiving chamber 7 connected to the front anti-collision beam 1, and an energy absorption chamber 8 connected to the outer wall of the receiving chamber 7.

[0054] The cross section of the energy absorption cavity 8 is rectangular, and the energy absorption cavity is divided into multiple independent chambers by crisscross partitions. The center lines of the multiple independent chambers are parallel, and the center lines of the multiple chambers are perpendicular to the accommodating cavity 7, which can absorb energy step by step during a collision and slow down the transmission of the impact force.

[0055] Partition design: The energy absorption cavity 8 is divided into a first cavity and a second cavity along the centerline direction of the accommodating cavity 7 by the first partition 9, and the cross-sectional area of ​​the second cavity is larger than the cross-sectional area of ​​the first cavity.

[0056] In the first and second chambers, a plurality of second baffles 10 and third baffles 11 are respectively arranged perpendicular to the first baffle 9 to further enhance the energy absorption effect.

[0057] Manufacturing process adjustment: In the semi-solid aluminum casting process, the above-mentioned complex structure can be formed in one piece by optimizing the mold design. The casting parameters are adjusted to ensure that the aluminum alloy is completely filled in the complex cavity to avoid defects.

[0058] Example 3

[0059] This embodiment provides a method for manufacturing a steel-aluminum hybrid front anti-collision beam structure, which is used to manufacture the steel-aluminum hybrid front anti-collision beam structure in Embodiment 1 and Embodiment 2, and the method comprises the following steps:

[0060] 1. Manufacturing of front anti-collision beam 1:

[0061] High-strength steel plates are selected and welded into rectangular closed straight tube beams using high-frequency welding technology.

[0062] 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 front of the vehicle.

[0063] A front towing ring connecting sleeve mounting hole 13 is reserved on the front anti-collision beam 1 for mounting the front towing ring connecting sleeve 6 .

[0064] 2. Manufacturing and connection of energy absorption boxes 2 and 3:

[0065] Mold preheating: Preheat the semi-solid aluminum casting mold to 220-240°C to ensure stable temperature during the casting process.

[0066] Placing the front bumper beam 1: placing the formed front bumper beam 1 into the preheated mold cavity and positioning it accurately.

[0067] Heating and injection of aluminum alloy:

[0068] Heat the aluminum alloy to 570-590°C to reach the semi-solid temperature range.

[0069] 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.

[0070] 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 front bumper beam 1 without pores and shrinkage.

[0071] Cooling and removal:

[0072] The casting is cooled to the mold temperature through the water channel in the mold, and the cooling time is about 30 seconds.

[0073] The mold is opened, and the energy absorption boxes 2, 3 and the front anti-collision beam 1 which have been connected as a whole are taken out, and cooled at room temperature.

[0074] 3. Installation of energy absorption box mounting plates 4 and 5:

[0075] The energy absorption box mounting plate is made of aluminum alloy, and the cylindrical pins and bolt holes are processed according to the design requirements.

[0076] The energy absorption box mounting plate is connected to the ends of the energy absorption boxes 2 and 3 by welding to ensure a firm connection.

[0077] In some embodiments of the present invention, the front traction ring connecting sleeve 6 is first inserted into the mounting hole 13 reserved in the front anti-collision beam 1 and fixed by welding. Then, the front anti-collision beam welded with the front traction ring connecting sleeve 6 is placed in the mold.

[0078] Example 4

[0079] This embodiment provides a method for manufacturing a steel-aluminum hybrid front anti-collision beam structure, which is used to manufacture the steel-aluminum hybrid front anti-collision beam structure in Embodiment 1 and Embodiment 2, and the method comprises the following steps:

[0080] 1. Manufacturing of front anti-collision beam:

[0081] (1) Cut the high-strength steel plate into the required size and form it by roll forming.

[0082] (2) High-frequency welding is used to form a closed cross section.

[0083] (3) Forming it into the desired shape through the pipe bending process.

[0084] (4) Weld the front traction ring connecting sleeve into place.

[0085] (5) Grind the welds and surfaces.

[0086] (6) Degreasing and rust removal of the surface.

[0087] (7) Spray high temperature resistant anti-stick coating.

[0088] 2. Semi-solid casting process:

[0089] (1) Preheat the mold to 220-240°C.

[0090] (2) Heat the AlSi7Mg alloy to 570-590°C.

[0091] (3) Place the front anti-collision beam into the mold cavity.

[0092] (4) Inject the semi-solid alloy at a speed of 3 to 4 m / s.

[0093] (5) Increase the pressure to 160-180 MPa.

[0094] (6) Control the temperature at 630-650℃.

[0095] (7) Maintain pressure for more than 3 seconds.

[0096] (8) Cooling through water channels.

[0097] (9) Demolding and post-processing.

[0098] 3. Assembly process:

[0099] (1) Install the rivet nut into the reserved hole of the front bumper beam.

[0100] (2) Press the cylindrical pin onto the energy absorption box mounting plate.

[0101] (3) Carry out dimensional inspection and strength test on the whole.

[0102] Example 5

[0103] This embodiment provides an assembly method, comprising the following steps:

[0104] 1. Pre-assembly in welding workshop:

[0105] In the welding workshop, the front anti-collision beam assembly is temporarily fixed to the left and right front longitudinal beam assemblies of the vehicle body by three M8 bolts on each side to ensure that it is processed synchronously with the vehicle body during the painting process.

[0106] 3. Painting treatment:

[0107] As the body-in-white enters the paint shop, the surface of the front bumper beam assembly undergoes electrophoretic coating to increase corrosion resistance.

[0108] 4. Formal installation in the final assembly workshop:

[0109] After painting is completed, the front bumper beam assembly is removed from the vehicle body in the final assembly workshop and placed in a material box. After the chassis assembly is completed, the front bumper beam assembly is fixed to the vehicle body with three M8 bolts on each side to complete the installation.

[0110] Example 6

[0111] This embodiment provides a vehicle using the above steel-aluminum hybrid front anti-collision beam structure. The vehicle can be a traditional fuel vehicle or a new energy vehicle.

[0112] The present invention adopts a steel-aluminum hybrid structure. The front anti-collision beam is made of high-strength steel to ensure structural strength; the energy absorption box is made of aluminum alloy material to achieve lightweight, and at the same time, the energy absorption effect is improved through reasonable structural design.

[0113] The present invention adopts a semi-solid aluminum casting process to connect the front anti-collision beam and the energy absorption box into a whole, avoiding the problem of insufficient strength caused by the traditional welding process, improving the strength and rigidity of the connection, and simplifying the production process.

[0114] The energy absorption box of the present invention adopts a multi-chamber design, improves the energy absorption effect by rationally arranging the partitions, and enhances the collision safety of the vehicle.

[0115] The present invention eliminates the traditional steel plate stamping and welding structure, reduces welding procedures, reduces production costs, and improves production efficiency.

[0116] Through the detailed description of the above embodiments, the present invention provides a steel-aluminum hybrid front anti-collision beam structure and a manufacturing method thereof that integrates high strength, light weight and low cost. The structure fully utilizes the advantages of high-strength steel and aluminum alloy materials, adopts advanced semi-solid aluminum casting technology, realizes the integrated molding of the front anti-collision beam and the energy absorption box, simplifies the production process, reduces costs, and improves product quality and vehicle safety performance.

[0117] The specific values ​​in all embodiments can be adjusted within the range of ±10%, and as long as they do not deviate from the technical solution of the present invention, they should be regarded as the protection scope of the present invention. Those skilled in the art can change and modify the above embodiments according to actual needs, and these changes and modifications should be regarded as the protection scope of the present invention as long as they do not deviate from the technical solution of the present invention.

[0118] 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 front anti-collision beam structure, characterized in that: include: A front anti-collision beam made of high-strength steel plate is provided with an energy absorption box at both ends of the front anti-collision beam; the energy absorption box is connected to the front anti-collision beam into a whole by adopting 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 front anti-collision beam structure according to claim 1 is characterized by: The energy absorption box includes a receiving cavity connected to the front 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 front anti-collision beam structure according to claim 2 is characterized in that: The cross-section of the energy absorption cavity is rectangular, and the energy absorption cavity is divided into multiple chambers by criss-cross partitions; the center lines of the multiple chambers are parallel, and the center lines of the multiple chambers are perpendicular to the accommodating cavity; the energy absorption cavity is divided into a first chamber and a second chamber along the center line direction of the accommodating cavity by a first partition, and the cross-sectional area of ​​the second chamber is larger than the cross-sectional area of ​​the second chamber.

4. The steel-aluminum hybrid front anti-collision beam structure according to claim 3 is characterized by: A plurality of second partitions perpendicular to the first partition are also provided in the first chamber; a plurality of third partitions perpendicular to the first partition are also provided in the second chamber.

5. The steel-aluminum hybrid front anti-collision beam structure according to claim 1 is characterized by: The front anti-collision beam is provided with a prefabricated through hole; the front towing ring connecting sleeve is connected to the front anti-collision beam through the prefabricated through hole for installing a trailer hook.

6. A method for manufacturing a steel-aluminum hybrid front anti-collision beam structure, used to manufacture the steel-aluminum hybrid front 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 front anti-collision beam is formed by a tube bending process; The front 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 is formed while the energy absorption box and the front anti-collision beam are cast into one body; The energy absorption box mounting plate is connected to the energy absorption box through welding process to complete the installation of the energy absorption box mounting plate.

7. The method for manufacturing a steel-aluminum hybrid front anti-collision beam structure according to claim 6, characterized in that: First, the front traction ring connecting sleeve is connected to the front anti-collision beam through a welding process, and then the front anti-collision beam is placed in the preheated mold cavity.

8. The method for manufacturing a steel-aluminum hybrid front anti-collision beam structure according to claim 6, characterized in that: Before placing the front bumper 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 3-4 m / s and a pressure of 70-80 MPa; after the semi-solid aluminum alloy is injected into the mold cavity: increase the pressure to 160-180 MPa; control the temperature between 630-650°C; and maintain the temperature and pressure for more than 2 seconds.

9. The method for manufacturing a steel-aluminum hybrid front 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 front anti-collision beam structure as claimed in any one of claims 1 to 5.

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