Aluminum alloy frame structure of new energy commercial vehicle

Abstract

The invention discloses a new energy commercial vehicle aluminum alloy frame structure which comprises a first aluminum alloy longitudinal beam (1) and a second aluminum alloy longitudinal beam (2), and the first aluminum alloy longitudinal beam (1) and the second aluminum alloy longitudinal beam (2) are of a symmetrical structure and are connected through a plurality of aluminum alloy connecting cross beams (3) and an aluminum alloy tail cross beam (4). The two ends of the aluminum alloy connecting cross beam (3) and the two ends of the aluminum alloy tail cross beam (4) are fixedly connected with the first aluminum alloy longitudinal beam (1) and the second aluminum alloy longitudinal beam (2) through bolt assemblies respectively. The vehicle frame has the advantages of light weight, high bearing capacity and convenience in assembly, the strength of the vehicle frame of the new energy commercial vehicle can be effectively ensured, and the economical efficiency of the battery is improved.

Description

Technical Field

[0001] This invention relates to a vehicle frame structure, and more particularly to an aluminum alloy vehicle frame structure for new energy commercial vehicles. Background Technology

[0002] Aluminum alloys, as a primary structural material for commercial vehicles, possess the following characteristics: Their density is approximately one-third that of steel, significantly reducing the overall weight of commercial vehicles and thus improving fuel economy and load-bearing capacity. Through alloying and heat treatment, aluminum alloys can achieve strength comparable to some high-strength steels, ensuring the safety and durability of the chassis. Aluminum alloys exhibit excellent corrosion resistance, making them particularly suitable for rainy or humid environments, reducing the frequency of maintenance and replacement. Aluminum alloys are easily processed through welding, extrusion, and casting, making them suitable for large-scale production and mass manufacturing. Appropriate aluminum alloy series can be selected based on the functional requirements of different commercial vehicles to achieve the optimal balance between performance and cost. Aluminum alloy materials can be used to form complex chassis structures through stamping, forging, and extrusion processes, which enable high-precision and high-strength manufacturing requirements.

[0003] Aluminum alloy extrusion is the process of extrudeing metal billets through a die within an extrusion cylinder to form the desired shape. Aluminum alloys are well-suited for this process due to their good plasticity and low melting point. Extrusion can manufacture profiles with various complex cross-sections, such as those with grooves or bosses, which is difficult to achieve with other processes. High material utilization: Extrusion results in less material loss, leading to higher material utilization and cost savings compared to machining. Good mechanical properties: The high temperature during extrusion refines the metal grains, resulting in a more uniform microstructure and improved strength and toughness, comparable to forging. Relatively low investment in molds and manufacturing processes.

[0004] In the existing technology, the chassis of light trucks adopts a steel chassis with a straight longitudinal beam structure. The materials are mostly 510L beam steel and QSTE650 high-strength steel. The steel chassis includes a pair of longitudinally extending longitudinal beams, which are composed of multiple transversely extending crossbeams. The longitudinal beams and crossbeams are generally U-shaped structures. The longitudinal beams and crossbeams are connected by connecting plates. The connecting plates are connected to the longitudinal beams and to the crossbeams by bolts and nuts or by riveting and welding. The chassis assembly process is complex and there are many installation points. Summary of the Invention

[0005] The purpose of this invention is to provide an aluminum alloy frame structure for new energy commercial vehicles to solve the technical problems in the prior art. It has the advantages of light weight, strong load-bearing capacity and convenient assembly, and can effectively ensure the frame strength of new energy commercial vehicles and improve battery economy.

[0006] This invention provides an aluminum alloy frame structure for a new energy commercial vehicle, including a first aluminum alloy longitudinal beam and a second aluminum alloy longitudinal beam. The first and second aluminum alloy longitudinal beams are symmetrical and are connected by multiple aluminum alloy connecting crossbeams and a rear aluminum alloy crossbeam. The two ends of the connecting crossbeams and the rear aluminum alloy crossbeam are respectively fixedly connected to the first and second aluminum alloy longitudinal beams by bolt assemblies.

[0007] In the aforementioned aluminum alloy frame structure for new energy commercial vehicles, preferably, the number of aluminum alloy connecting beams is at least four.

[0008] In the aforementioned aluminum alloy frame structure for new energy commercial vehicles, preferably, the aluminum alloy connecting crossbeam includes an aluminum alloy crossbeam body, an upper fixed bracket, and a lower support bracket. The aluminum alloy crossbeam body has a symmetrical structure and includes an upper crossbeam, a lower crossbeam, and a support beam. The width of the upper crossbeam is smaller than the width of the lower crossbeam, and the upper crossbeam is fixedly connected to the lower crossbeam through two support beams.

[0009] In the aforementioned aluminum alloy frame structure for new energy commercial vehicles, preferably, the two supporting beams are arranged symmetrically in a figure-eight shape.

[0010] In the aforementioned aluminum alloy frame structure for new energy commercial vehicles, preferably, a bracket mounting hole is provided at each of the four corners of the upper crossbeam, the number of upper fixed brackets is four, the four upper fixed brackets have the same structure, the upper fixed bracket includes a connecting pipe and a connecting plate, two parallel connecting plates are fixed on the outer wall of the connecting pipe, the distance between the two connecting plates is equal to the thickness of the upper crossbeam, and mounting holes are provided on the two connecting plates.

[0011] In the aforementioned aluminum alloy frame structure for new energy commercial vehicles, preferably, a lower support bracket is installed at the bottom of each end of the lower crossbeam. The two lower support brackets are symmetrical structures, each including an L-shaped support plate, a first inclined support plate, and a second inclined support plate. The corner of the L-shaped support plate is rounded. The first inclined support plate is fixed between the top wall and the side wall of the L-shaped support plate. The corner of the first inclined support plate and the L-shaped support plate are fixedly connected by the second inclined support plate.

[0012] In the aforementioned aluminum alloy frame structure for new energy commercial vehicles, preferably, the first aluminum alloy longitudinal beam and the second aluminum alloy longitudinal beam are U-shaped integrated longitudinal beams, the thickness of the upper and lower parts of the sidewalls of the first aluminum alloy longitudinal beam and the second aluminum alloy longitudinal beam is greater than the thickness of the middle part of the sidewall, and the thickness of the top and bottom walls of the first aluminum alloy longitudinal beam and the second aluminum alloy longitudinal beam is the same as the thickness of the upper and lower parts of the sidewall.

[0013] Compared with existing technologies, this invention includes an aluminum alloy first longitudinal beam, an aluminum alloy second longitudinal beam, multiple aluminum alloy connecting crossbeams, and an aluminum alloy rear crossbeam. The entire invention is made of aluminum alloy, which not only increases the strength of the frame but also reduces the number of reinforcing plates and lowers the frame weight. The reduction in components simplifies the assembly process, making production and installation easier. This invention is suitable for new energy commercial vehicles, as the overall weight reduction effectively improves battery range. Attached Figure Description

[0014] Figure 1 This is an isometric view of the present invention;

[0015] Figure 2 It is an assembly drawing of the aluminum alloy crossbeam body, the upper fixed bracket, and the lower support bracket;

[0016] Figure 3 This is an end view of the main body of the aluminum alloy beam;

[0017] Figure 4 This is an end view of the upper fixed bracket;

[0018] Figure 5 This is an end view of the lower support bracket;

[0019] Figure 6 This is the end view of the first longitudinal beam made of aluminum alloy.

[0020] Explanation of reference numerals in the attached drawings: 1. First longitudinal beam of aluminum alloy; 2. Second longitudinal beam of aluminum alloy; 3. Connecting crossbeam of aluminum alloy; 4. Tail crossbeam of aluminum alloy; 5. Main body of aluminum alloy crossbeam; 6. Upper fixed bracket; 7. Lower support bracket; 8. Upper crossbeam; 9. Lower crossbeam; 10. Support beam; 11. Connecting pipe; 12. Connecting plate; 13. L-shaped support plate; 14. First inclined support plate; 15. Second inclined support plate; 16. Crossbeam mounting hole. Detailed Implementation

[0021] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0022] Embodiments of the present invention: such as Figures 1-6 As shown, an aluminum alloy frame structure for a new energy commercial vehicle includes an aluminum alloy first longitudinal beam 1 and an aluminum alloy second longitudinal beam 2. The aluminum alloy first longitudinal beam 1 and the aluminum alloy second longitudinal beam 2 are symmetrical structures and are connected by multiple aluminum alloy connecting crossbeams 3 and an aluminum alloy rear crossbeam 4. The two ends of the aluminum alloy connecting crossbeams 3 and the aluminum alloy rear crossbeam 4 are respectively fixedly connected to the aluminum alloy first longitudinal beam 1 and the aluminum alloy second longitudinal beam 2 by bolt assemblies.

[0023] The aluminum alloy first longitudinal beam 1 and aluminum alloy second longitudinal beam 2 of the present invention are integrally extruded. Compared with traditional steel longitudinal beams, a large number of reinforcing plates are eliminated, the overall weight is reduced, the battery range is improved, and the strength is higher than that of traditional steel longitudinal beams.

[0024] The number of aluminum alloy connecting crossbeams 3 is set according to actual needs; in this embodiment, four are preferred. The aluminum alloy connecting crossbeams 3 are also integrally extruded, offering advantages of high strength and low weight. The shape of the aluminum alloy rear crossbeam 4 is the same as that of the rear crossbeam on existing vehicle frames; therefore, the specific shape of the aluminum alloy rear crossbeam 4 will not be described in detail in this embodiment.

[0025] Furthermore, the aluminum alloy connecting beam 3 includes an aluminum alloy beam body 5, an upper fixed bracket 6, and a lower support bracket 7. The aluminum alloy beam body 5 has a symmetrical structure and includes an upper beam 8, a lower beam 9, and a support beam 10. The width of the upper beam 8 is smaller than the width of the lower beam 9. The upper beam 8 is fixedly connected to the lower beam 9 through two support beams 10.

[0026] The upper crossbeam 8, the lower crossbeam 9, and the support beam 10 are all of equal length, and the two support beams 10 are arranged symmetrically in a figure-eight shape.

[0027] The two support beams 10, together with the upper crossbeam 8 and the lower crossbeam 9, form a trapezoidal space that is larger at the top and smaller at the bottom, which improves the load-bearing capacity of the aluminum alloy crossbeam body 5 and also achieves lightweighting.

[0028] A bracket mounting hole (not shown in the figure) is opened at each of the four corners of the upper crossbeam 8. There are four upper fixed brackets 6, and the four upper fixed brackets 6 have the same structure. The upper fixed bracket 6 includes a connecting pipe 11 and a connecting plate 12. Two parallel connecting plates 12 are fixed on the outer wall of the connecting pipe 11. The distance between the two connecting plates 12 is equal to the thickness of the upper crossbeam 8. Mounting holes (not shown in the figure) are opened on the two connecting plates 12.

[0029] During installation, use two connecting plates 12 to clamp the upper crossbeam 8, then align the mounting holes with the bracket mounting holes on the upper crossbeam 8, and fix them together using bolt assemblies or rivets.

[0030] A row of crossbeam mounting holes 16 are machined on the upper and lower parts of the side walls of the aluminum alloy first longitudinal beam 1 and the aluminum alloy second longitudinal beam 2, respectively. Bolts are passed through the connecting pipe 11 and the corresponding crossbeam mounting holes 16, and then nuts are used for fixing.

[0031] The upper crossbeam 8 is fixed by four upper fixed brackets 6, which improves the stability of the fixation.

[0032] At the bottom of each end of the lower crossbeam 9, there is a lower support bracket 7. The two lower support brackets 7 are symmetrical structures. Both of them include an L-shaped support plate 13, a first inclined support plate 14, and a second inclined support plate 15. The corner of the L-shaped support plate 13 is rounded. The first inclined support plate 14 is fixed between the top wall and the side wall of the L-shaped support plate 13. The corner of the first inclined support plate 14 and the L-shaped support plate 13 are fixedly connected by the second inclined support plate 15.

[0033] The corner of the L-shaped support plate 13 is rounded, which improves the deformation resistance of the L-shaped support plate 13 and enables the L-shaped support plate 13 to effectively support the lower crossbeam 9.

[0034] The arrangement of the first inclined support plate 14 and the second inclined support plate 15 on the L-shaped support plate 13 creates two approximately triangular irregular spaces at the inner corner of the L-shaped support plate 13, further increasing the support strength and deformation resistance at the corner.

[0035] Furthermore, the aluminum alloy first longitudinal beam 1 and the aluminum alloy second longitudinal beam 2 are U-shaped integrated longitudinal beams. The thickness of the upper and lower parts of the sidewalls of the aluminum alloy first longitudinal beam 1 and the aluminum alloy second longitudinal beam 2 is greater than the thickness of the middle part of the sidewalls. The thickness of the top and bottom walls of the aluminum alloy first longitudinal beam 1 and the aluminum alloy second longitudinal beam 2 are the same as the thickness of the upper and lower parts of the sidewalls.

[0036] The extruded first longitudinal beam 1 and aluminum alloy second longitudinal beam 2 can directly reinforce the areas requiring reinforcement. Since the middle of the sidewalls of the first longitudinal beam 1 and the aluminum alloy second longitudinal beam 2 experiences less stress, their thickness can be reduced, lowering the overall weight and saving materials. This eliminates the need for reinforcing plates in existing steel longitudinal beams, reducing assembly difficulty.

[0037] The above description, based on the embodiments shown in the figures, details the structure, features, and effects of the present invention. The above description is only a preferred embodiment of the present invention, but the present invention is not limited to the scope of implementation shown in the figures. Any changes made in accordance with the concept of the present invention, or equivalent embodiments modified to have equivalent changes, that do not exceed the spirit covered by the specification and figures, should be within the protection scope of the present invention.

Claims

1. An aluminum alloy frame structure for a new energy commercial vehicle, characterized in that: It includes an aluminum alloy first longitudinal beam (1) and an aluminum alloy second longitudinal beam (2). The aluminum alloy first longitudinal beam (1) and the aluminum alloy second longitudinal beam (2) are symmetrical structures. They are connected by multiple aluminum alloy connecting crossbeams (3) and an aluminum alloy tail crossbeam (4). The two ends of the aluminum alloy connecting crossbeams (3) and the aluminum alloy tail crossbeam (4) are fixedly connected to the aluminum alloy first longitudinal beam (1) and the aluminum alloy second longitudinal beam (2) respectively by bolt assemblies.

2. The aluminum alloy frame structure for new energy commercial vehicles according to claim 1, characterized in that: The number of aluminum alloy connecting beams (3) is at least four.

3. The aluminum alloy frame structure for new energy commercial vehicles according to claim 1, characterized in that: The aluminum alloy connecting beam (3) includes an aluminum alloy beam body (5), an upper fixed bracket (6) and a lower support bracket (7). The aluminum alloy beam body (5) has a symmetrical structure. The aluminum alloy beam body (5) includes an upper beam (8), a lower beam (9) and a support beam (10). The width of the upper beam (8) is smaller than the width of the lower beam (9). The upper beam (8) is fixedly connected to the lower beam (9) through two support beams (10).

4. The aluminum alloy frame structure for new energy commercial vehicles according to claim 3, characterized in that: The two support beams (10) are arranged symmetrically in a figure-eight shape.

5. The aluminum alloy frame structure for new energy commercial vehicles according to claim 3, characterized in that: The upper crossbeam (8) has a bracket mounting hole at each of its four corners. There are four upper fixed brackets (6), and the four upper fixed brackets (6) have the same structure. The upper fixed bracket (6) includes a connecting pipe (11) and a connecting plate (12). Two parallel connecting plates (12) are fixed on the outer wall of the connecting pipe (11). The distance between the two connecting plates (12) is equal to the thickness of the upper crossbeam (8). The two connecting plates (12) have mounting holes.

6. The aluminum alloy frame structure for new energy commercial vehicles according to claim 3, characterized in that: At the bottom of each end of the lower crossbeam (9), a lower support bracket (7) is installed. The two lower support brackets (7) are symmetrical structures. Both include an L-shaped support plate (13), a first inclined support plate (14), and a second inclined support plate (15). The corner of the L-shaped support plate (13) is a rounded transition. The first inclined support plate (14) is fixed between the top wall and the side wall of the L-shaped support plate (13). The corner of the first inclined support plate (14) and the L-shaped support plate (13) are fixedly connected by the second inclined support plate (15).

7. The aluminum alloy frame structure for new energy commercial vehicles according to claim 6, characterized in that: The aluminum alloy first longitudinal beam (1) and the aluminum alloy second longitudinal beam (2) are U-shaped integrated longitudinal beams. The thickness of the upper and lower parts of the sidewalls of the aluminum alloy first longitudinal beam (1) and the aluminum alloy second longitudinal beam (2) is greater than the thickness of the middle part of the sidewalls. The thickness of the top and bottom walls of the aluminum alloy first longitudinal beam (1) and the aluminum alloy second longitudinal beam (2) is the same as the thickness of the upper and lower parts of the sidewalls.

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