New energy heavy truck integrated frame middle section structure and implementation method thereof

Abstract

According to the integrated frame middle section structure based on die-casting manufacturing and the implementation method of the integrated frame middle section structure, a bearing piece in the middle section structure of a three-section type heavy truck frame is achieved in the form of a large single part, optimization design is conducted on material distribution in a given area on an initial thick plate, and a thickened framework is arranged on a large-load part; the part with smaller load is thinned, and is manufactured based on a die-casting process, so that the use of fasteners of the middle section structure of the frame is avoided, the assembly procedures are reduced, and the material distribution of the bearing structure is more reasonable; the utilization rate of available space in the middle frame is greatly improved, the layout flexibility is improved, meanwhile, the light weight level of the middle frame is improved, and the waterproof effect is also improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of heavy truck design and manufacturing, in particular to an integrated middle section structure of a three-section heavy truck frame based on die casting manufacturing and an implementation method thereof. BACKGROUND

[0002] In the existing three-section design of heavy truck frames, the middle section structure is usually a frame structure with beam structures as units. This structure often leads to limited space utilization of the middle section structure, limited lightweight degree of the whole, and unsatisfactory waterproof effect of the middle section frame space. In the design of new energy heavy trucks, due to the need to place batteries, higher requirements are put forward for the space utilization of the middle section. The existing middle section structure cannot meet the requirements, and the waterproof effect is also poor due to the splicing of multiple components. SUMMARY

[0003] The present application proposes an integrated middle section structure of a heavy truck frame based on die casting manufacturing and an implementation method thereof to solve the problems of low space utilization, insufficient lightweight degree, and poor waterproof performance caused by the limitation of beam structure in the existing heavy truck frame design, and the deficiency that the existing car frame design technology cannot be applied to heavy truck frames. The load-bearing member in the middle section structure of the three-section heavy truck frame is realized in the form of a large monolithic part. The material distribution is optimized in the given area on the initial thick plate. The skeleton is thickened in the parts with larger load, and the parts with smaller load are thinned. The manufacturing is based on the die casting process, which avoids the use of fasteners in the middle section structure of the frame, reduces the assembly process, makes the material distribution of the load-bearing structure more reasonable, greatly improves the space utilization of the middle section frame, and improves the lightweight level and waterproof effect of the middle section frame.

[0004] The present application is implemented by the following technical solutions:

[0005] The present application relates to an integrated middle section structure of a heavy truck frame based on die casting manufacturing, comprising: an integrated middle section structure load-bearing member manufactured by die casting process, an accessory mounting frame located on the side thereof, and an accessory mounting plate located at the bottom thereof, wherein: the integrated middle section structure load-bearing member and the accessory mounting plate constitute the available space in the middle section frame.

[0006] The integrated middle section structure load-bearing member is a monolithic part, comprising: a skeleton designed according to the stress distribution under different vehicle stress load conditions, a sealing plate, and a connecting joint, wherein: the sealing plates are arranged on the skeleton, and the connecting joints are located at both ends of the skeleton.

[0007] The skeleton, the sealing plate, and the connecting joint are preferably integrally formed by die casting.

[0008] The application relates to a realization method of the above-mentioned integrated frame middle section structure manufactured by die casting, and comprises the following steps:

[0009] Step 1) determining the overall stress working condition load condition and design standard of the frame;

[0010] The load condition comprises a two times gravity vertical bending working condition, a frame torsion working condition, a braking working condition, a steering working condition and the like.

[0011] The design standard comprises maximum equivalent stress, deformation amount, middle section internal space size and shape, manufacturability and manufacturing and assembling cost under each working condition.

[0012] Step 2) determining the size of a middle section thick plate of a basic shape of a middle section structure bearing according to the overall stress working condition load condition and design standard of the frame determined in step 1, and determining the form of connecting joints at two ends of the middle section structure bearing according to the form of joints of front and rear sections of the frame;

[0013] Step 3) adopting CAE software, combining the design of the three-section frame front and rear sections and the basic shape design of the integrated frame middle section structure bearing in step 2, and adopting statics analysis according to the stress working condition load condition determined in step 1 to obtain stress distribution under the stress working condition.

[0014] Step 4) performing geometric optimization of the middle section structure bearing, arranging a skeleton along a high stress distribution path, and thinning the material of a low stress part to form a sealing plate.

[0015] The geometric optimization refers to size optimization and shape optimization of material distribution in a given area based on the stress distribution obtained in step 3.

[0016] The arrangement position of the skeleton is obtained by using topology optimization to obtain a topology optimization result cloud map.

[0017] Step 5) re-adjusting the geometrically optimized middle section structure bearing based on manufacturability and feasibility.

[0018] The re-adjustment refers to judging the structure part which is not realizable by high-pressure die casting in the geometric optimization result of step 4 through manufacturing process simulation, and modifying the structure part.

[0019] Step 6) adopting CAE software to check the result re-adjusted in step 5 in combination with the design standard determined in step 1, returning to step 5 to re-adjust again if the checking fails, and completing the design until the checking is passed.

[0020] Step 7) performing integrated high-pressure die casting manufacturing on the middle section structure bearing which passes the checking in step 6. Technical effects

[0021] The application adopts an integrated frame middle section structure, avoids the use of fasteners of the frame middle section structure, reduces assembly procedures, makes material distribution of the bearing structure more reasonable, greatly improves the space utilization rate available in the middle section frame, has higher layout flexibility, meanwhile improves the light weight level of the middle section frame and the waterproof effect. BRIEF DESCRIPTION OF DRAWINGS

[0022] Figure 1 It is a schematic view of the integrated frame middle section structure bearing;

[0023] Figure 2 (a) and (b) are three-dimensional perspective views of the integrated frame middle section structure of the heavy truck of the application, respectively;

[0024] Figure 3 (a)-(d) are engineering drawings of the integrated frame middle section structure of the heavy truck without the accessory mounting plate;

[0025] Figure 4 (a) and (b) are installation schematic views of the integrated frame middle section structure of the heavy truck of the application;

[0026] Figure 5 It is a flowchart of the application;

[0027] In the figure: accessory mounting frame 1, integrated frame middle section structure bearing 2, accessory mounting plate 3, skeleton 4, connecting joint 5, sealing plate 6, rear section of frame 7, middle section of frame 8, front section of frame 9, bolt mounting hole 10, connecting position 11. DETAILED DESCRIPTION

[0028] As Figure 2 (a) and (b) show an integrated frame middle section structure based on die casting manufacturing according to the present embodiment, which comprises: an integrated frame middle section structure bearing 2 manufactured by die casting process, an accessory mounting frame 1 located on the side thereof and an accessory mounting plate 3 located on the bottom thereof, wherein: the integrated frame middle section structure bearing 2 and the accessory mounting plate 3 constitute the available space in the middle section frame.

[0029] As Figure 1 shown, the integrated frame middle section structure bearing 2 comprises: a skeleton 4, a sealing plate 6 and a connecting joint 5 designed according to the stress distribution under different vehicle stress load conditions, wherein: a plurality of sealing plates 5 are arranged on the skeleton 4, and the connecting joint 5 is located at both ends of the skeleton 4.

[0030] The integrated frame middle section structure bearing 2 is preferably integrally formed by die casting in the manufacturing process.

[0031] As Figure 4 shown in (b), the connecting joint is further provided with a bolt mounting hole 10.

[0032] The skeleton is designed according to stress distribution under different vehicle stress working condition load conditions. Figure 1 The layout of the skeleton shown in the Y-shaped plus parallel strip form is only an example, and different from the layout of the skeleton shown in various shapes and sizes, such as the herringbone shape, the inverted V-shaped form, the I-shaped form, etc. Figure 1 The layout of the skeleton shown in various shapes and sizes, such as the herringbone shape, the inverted V-shaped form, the I-shaped form, etc.

[0033] As shown in Figure 4 (a), the two ends of the integrated frame middle section structure are fixedly connected with the frame rear section 7 and the frame front section 9 through the connecting joints 5, respectively.

[0034] As shown in Figure 5 The implementation method of the above heavy truck frame integrated frame middle section structure load bearing part related to the embodiment includes the following steps.

[0035] Firstly, according to the design requirements of the heavy truck frame, the overall stress working condition load conditions and design standards of the frame are determined.

[0036] The load conditions include: two times gravity vertical bending working condition, frame torsion working condition, braking working condition, steering working condition, etc.

[0037] The vertical bending working condition may be, for example: the frame four-suspension hinged support, 5000N vertical downward concentrated force load on the left and right sides of the middle section of the frame. A 1.5t vehicle head mass load is applied at the vehicle head part of the frame, a 6t battery mass load is applied at the middle section, a 13t cargo mass load is applied near the connection between the rear section and the heavy truck trailer section, and a 2 times gravity acceleration is set.

[0038] The torsion working condition may be, for example: two rear suspensions hinged support, 1000N vertical upward concentrated force load on the left front suspension, and 1000N vertical downward concentrated force load on the right front suspension.

[0039] The design standards include: the maximum equivalent stress, deformation, internal space size and shape of the middle section (determined according to the requirements of vehicle type, battery capacity and type), manufacturability and manufacturing and assembly cost, etc.

[0040] Secondly, the basic shape of the integrated frame middle section structure load bearing part is determined, which is in the form of a thick plate in the middle plus connecting joints at both ends. The size of the thick plate is determined according to the design standards determined in the first step, and the form of the connecting joints at both ends of the middle section structure load bearing part is determined according to the form of the front and rear frame joints. Specifically, the connecting joints shown in Figs. 4a and 4b are designed according to the structure and size of the front and rear frame joints, to complete the initial design of the integrated frame middle section structure as shown in Figure 4 Figure 6 a, 4b.​

[0041] The material of the thick plate can be selected from aluminum alloy, etc.

[0042] The length and width of the thick plate cover the entire middle section structure, and the initial thickness of the thick plate is set in the range of 15mm-300mm, which can be adjusted according to the design load of the heavy truck, the size and position of the battery space to be reserved.

[0043] In the third step, the CAE software is used to combine the design of the front and rear sections of the three-section frame and the basic shape design of the integrated frame middle section structure bearing in the second step, and the static analysis is performed according to the load conditions determined in the first step to obtain the stress distribution under the load conditions.

[0044] In the fourth step, the geometric optimization of the integrated frame middle section structure bearing is performed, and based on the stress distribution obtained in the third step, the size and shape of the material distribution in the given area of the middle section thick plate are optimized. The skeleton is arranged along the high stress distribution path, and the material in the low stress part is thinned to form a sealing plate, which specifically includes:

[0045] The topology optimization result cloud map under various load conditions is obtained by using topology optimization, and the shape optimization is completed according to the material distribution scheme given by the topology optimization result cloud map, as shown in Figure 7 .

[0046] In the fifth step, it is determined whether there is a structure part that cannot be manufactured by high-pressure die casting in the optimization result in the fourth step through manufacturing process simulation (such as CAM software). If there is, the optimization result in the fourth step is re-adjusted according to the unmanufacturable reasons and considering the restrictions such as the battery arrangement space requirement determined in the first step, to obtain an actual feasible integrated frame middle section structure that meets the requirements of manufacturability or symmetry, etc.

[0047] In the sixth step, the CAE software is used to check the result of the fifth step to determine whether it meets the load conditions and design standards of the overall frame determined in the first step. If the check passes, the design is completed, and if the check fails, it returns to the fifth step for re-adjustment. Specifically, CAE simulation analysis is performed based on the multiple heavy truck load conditions and design standards determined in the first step to ensure that the mechanical performance, manufacturability, cost and middle section space of the frame meet the design standards.

[0048] In the seventh step, the middle section structure bearing designed in the previous steps is manufactured by integrated high-pressure die casting.

[0049] Compared with the prior art, the integrated frame middle section structure load-bearing part is a single part, avoiding the use of frame middle section structure fasteners, reducing the assembly process, making the load-bearing structure material distribution more reasonable, thereby greatly improving the space utilization rate available inside the middle section frame, improving the lightweight level of the middle section frame, and also providing a certain waterproof effect for the middle section frame space. In addition, according to the method of the present application, various different shapes and sizes of skeleton layouts can be presented in the integrated frame middle section structure load-bearing part designed according to different vehicle models, battery capacities and placement positions. Compared with the prior art, the layout flexibility is higher.

[0050] The inventor also conceives that the integrated frame middle section structure load-bearing part of the present application can be further integrated with the battery shell structure part.

[0051] The above specific embodiments can be adjusted in different ways by those skilled in the art without departing from the principles and purposes of the present application, the protection scope of the present application is subject to the claims and is not limited by the above specific embodiments, and each implementation scheme within the scope is subject to the constraints of the present application.

Claims

1. An integrated mid-section frame structure manufactured based on die casting, characterized by, The application relates to an integrated frame middle section structure load-bearing piece, an accessory mounting frame on the side thereof and an accessory mounting plate on the bottom thereof which are integrally manufactured through a die casting process, wherein the integrated frame middle section structure load-bearing piece and the accessory mounting plate constitute available space in a middle section frame. The integrated frame middle section structure load-bearing piece is a single part which comprises a framework, sealing plates and connecting joints and is designed according to stress distribution under different vehicle stress working conditions, wherein the sealing plates are arranged on the framework, and the connecting joints are located at two ends of the framework.

2. The integrated mid-section structure of die-cast based vehicle frame according to claim 1, characterized in that, The framework, the sealing plates and the connecting joints are integrally formed through die casting. Further bolt mounting holes are arranged on the connecting joints.

3. The integrated mid-section structure of a die-cast based vehicle frame according to claim 2, characterized in that, The application further relates to a design method of the integrated frame middle section structure load-bearing piece.

4. A method for manufacturing the integrated middle frame structure of any one of claims 1-3 by die casting, characterized in that, Step 1) determining the stress working condition load of the whole frame and design standards; Step 2) determining the size of a basic shape middle section thick plate of the middle section structure load-bearing piece according to the design standards determined in step 1, and determining the form of the connecting joints at two ends of the middle section structure load-bearing piece according to the joint form of front and rear sections of a three-section frame; Step 3) combining the design of the front and rear sections of the three-section frame and the basic shape design of the integrated frame middle section structure load-bearing piece in step 2, and adopting statics analysis according to the stress working condition load determined in step 1 to obtain stress distribution under the stress working condition; Step 4) geometric optimization of the middle section structure load-bearing piece, arranging the framework along the high stress distribution path, and thinning the material in the low stress part to form the sealing plate; The geometric optimization refers to size optimization and shape optimization of material distribution in a given area based on the stress distribution obtained in step 3; The arrangement position of the framework is obtained by using a topological optimization result cloud map; Step 5) re-adjusting the middle section structure load-bearing piece after the geometric optimization based on manufacturability and feasibility; The re-adjustment refers to modifying the structure part which is not realized through high-pressure die casting in the geometric optimization result in step 4 through manufacturing process simulation; Step 6) checking the result after the re-adjustment in step 5 in combination with the design standards determined in step 1, returning to step 5 for re-adjustment again if the checking fails, until the checking is passed, and the design is completed; Step 7) integrally manufacturing the middle section structure load-bearing piece which passes the checking in step 6 through high-pressure die casting. ​

Images