Commercial vehicle modular solid-state chassis and assembling method

Abstract

The invention discloses a commercial vehicle modular solid chassis and an assembling method, and relates to the technical field of automobile chassis, the commercial vehicle modular solid chassis comprises a steering module, the steering module comprises a first integrated mounting bracket, and a steering engine, a motor cooler, a steering axle, a front brake, a front extension beam, a front suspension and a 24V power supply which are mounted on the first integrated mounting bracket; the driving module comprises a second integrated mounting bracket, and an electric drive axle and a rear brake which are mounted on the second integrated mounting bracket; the energy storage module comprises a third integrated installation support, a battery pack, a battery cooling system, a high-voltage controller and an integrated controller, the battery pack, the battery cooling system, the high-voltage controller and the integrated controller are installed on the third integrated installation support, and the third integrated installation support is detachably connected with the first integrated installation support and the second integrated installation support; the solid chassis is subjected to modular design, and the modules are assembled in a general assembly workshop.

Description

Technical Field

[0001] This invention relates to the field of automotive chassis technology, and in particular to a modular solid chassis for commercial vehicles and its assembly method. Background Technology

[0002] Solid-state chassis is an innovative automotive chassis technology that integrates all-electric steering, all-electric braking, all-electric drive, and chassis domain control technology. In the current production model, the assembly of chassis components is entirely concentrated in the final assembly workshop.

[0003] Concentrating chassis parts in the final assembly workshop has the following disadvantages: the workload and complexity of the final assembly workshop are high, the demand for assembly stations is large, the required storage space is large, the management cost is high, and the maintenance time and cost are also high.

[0004] Therefore, there is an urgent need for a modular solid chassis for commercial vehicles. Summary of the Invention

[0005] The purpose of this invention is to provide a modular solid chassis for commercial vehicles and an assembly method to solve the problems existing in the prior art. The solid chassis is modularly designed, and the assembly between modules can be completed in the final assembly workshop.

[0006] To achieve the above objectives, the present invention provides the following solution: The present invention provides a modular solid-state chassis for commercial vehicles, comprising: a steering module, the steering module including a first integrated mounting bracket, and a steering gear, motor cooling, steering axle, front brake, front overhang beam, front suspension and 24V power supply mounted on the first integrated mounting bracket; a drive module, the drive module including a second integrated mounting bracket, and an electric drive axle and rear brake mounted on the second integrated mounting bracket; and an energy storage module, the energy storage module including a third integrated mounting bracket, and a battery pack, battery cooling system, high-voltage controller and integrated controller mounted on the third integrated mounting bracket, wherein the third integrated mounting bracket is detachably connected to the first integrated mounting bracket and the second integrated mounting bracket respectively.

[0007] Preferably, the outer periphery of the first integrated mounting bracket is covered by a first outer cover, and the outer periphery of the second integrated mounting bracket is covered by a second outer cover. Both the first and second outer covers are U-shaped, and the U-shaped openings of the first and second outer covers are both oriented toward the third integrated mounting bracket.

[0008] Preferably, the third integrated mounting bracket is provided with side skirts on both sides of the vehicle body.

[0009] Preferably, the side skirt guard plate includes a fixed plate and a sliding telescopic plate. The fixed plate is fixedly connected to the third integrated mounting bracket, and the sliding telescopic plate is slidably connected to the fixed plate. The sliding direction of the sliding telescopic plate is parallel to the length direction of the vehicle body.

[0010] Preferably, the fixed plate or the sliding telescopic plate is provided with a sliding groove, the sliding groove being parallel to the length direction of the vehicle body, and the sliding telescopic plate or the fixed plate is provided with a slide rail or slider, the slide rail or slider being slidably engaged with the sliding groove.

[0011] Preferably, the fixed plate or the sliding telescopic plate is provided with a sliding channel steel, and the inner cavity of the sliding channel steel is the sliding groove.

[0012] Preferably, a reinforcing bracket and / or vertical reinforcing ribs are provided between the fixed plate or the sliding telescopic plate and the sliding channel steel.

[0013] Preferably, the two ends of the side skirt guard are located inside the first outer cover and the second outer cover, respectively.

[0014] Preferably, the third integrated mounting bracket is provided with at least one strip hole, which is parallel to the length direction of the vehicle body. Both the first integrated mounting bracket and the second integrated mounting bracket are provided with multiple through holes, and the connecting screw passes through the strip hole and the through holes to connect with the nut.

[0015] The present invention also provides an assembly method for the above-mentioned modular solid chassis for commercial vehicles, comprising the following steps: S1: Connect the steering module and drive module to the frame, and after adjusting the positions of the steering module and drive module, fix them to the frame; S2: Insert the energy storage module into the frame from the bottom and position it between the steering module and the drive module; S3: Adjust the position of the energy storage module. After adjustment, connect the third integrated mounting bracket to the first integrated mounting bracket and the second integrated mounting bracket respectively.

[0016] The present invention achieves the following main technical effects compared to the prior art: After modularizing the solid chassis, each module is pre-assembled and tested in the supplier's factory before being sent to the final assembly workshop, which greatly reduces the workload and complexity of on-site assembly in the final assembly workshop.

[0017] Pre-installation inspection and debugging by the supplier can identify problems in advance, reducing the need to resolve issues in the final assembly workshop (such as system mismatch problems during assembly leading to creasing), and providing advantages in terms of quality reliability and production efficiency.

[0018] Once pre-installed, the modules can reduce warehouse storage space, simplify warehouse management, reduce some warehouse management costs, and improve inventory turnover.

[0019] The transportation model of delivering the three main modules directly from suppliers to the final assembly plant has replaced the previous decentralized parts supply and transportation process, which has reduced unit transportation costs to some extent.

[0020] All modules prioritize the use of highly reusable components, which can be reused in different models or projects. This avoids the cost of redeveloping the same or similar modules for each new model or project, reduces the investment of R&D manpower, time and money, and lowers development costs. The procurement response speed is greatly improved by purchasing the three major assemblies from suppliers. Large-scale production of models with the same configuration modules can also reduce procurement costs and supplier development and verification costs.

[0021] Generalization promotes collaborative development between parts suppliers and OEMs, allowing pre-installation requirements to be locked in in advance and reducing fluctuations in production plans.

[0022] When a module of a vehicle malfunctions, only the corresponding module needs to be replaced, without disassembling and repairing the entire chassis. This greatly reduces repair time and costs. In after-sales maintenance, efficient repairs can be achieved by replacing the faulty module, taking up less of the user's time and improving maintenance response speed. Moreover, when new technologies or parts become available, a single module can be upgraded or replaced without requiring large-scale modifications to the entire chassis.

[0023] The standardized components support modular pre-assembly, and the integrated design reduces assembly steps, lowers process complexity, and improves production line flexibility. At the same time, compared to assembling individual parts onto the chassis, it can save the number of assembly parts and reduce the number of assembly stations (assembly areas) required.

[0024] The highly reusable modules have been thoroughly validated and can be sold to other manufacturers in a standardized manner. Modular maintenance reduces labor costs, and module replacement services can be promoted to increase after-sales profits. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a schematic diagram of the steering module of the modular solid chassis for commercial vehicles in an embodiment of the present invention; Figure 2 This is a schematic diagram of the energy storage module of the modular solid-state chassis for commercial vehicles in an embodiment of the present invention; Figure 3 This is a schematic diagram of the drive module of the modular solid-state chassis for commercial vehicles in an embodiment of the present invention; Figure 4 This is a schematic diagram of the connection structure of the three integrated mounting brackets in an embodiment of the present invention; Figure 5 for Figure 4 Enlarged view of the structure at point A in the middle; Figure 6 This is a schematic diagram of the side skirt guard plate in an embodiment of the present invention; Figure 7 This is a schematic diagram of the connection structure between the three integrated mounting brackets and the vehicle frame in an embodiment of the present invention; Figure 8 This is a schematic diagram of the modular solid-state chassis for commercial vehicles in an embodiment of the present invention; The components are as follows: 1. Steering module; 1-1. Steering gear; 1-2. Motor cooling; 1-3. Steering axle; 1-4. Front brake; 1-5. Front suspension; 1-6. First outer cover; 1-7. 24V power supply; 1-8. First integrated mounting bracket; 2. Energy storage module; 2-1. Battery pack; 2-2. Battery cooling system; 2-3. Side skirt; 2-31. Fixing plate; 2-32. Sliding telescopic plate; 2-33. Sliding channel steel; 2-34. Reinforcing bracket; 2-35. Vertical reinforcing rib; 2-36. Embedded block; 2-4. High voltage controller; 2-5. Integrated controller; 2-6. Third integrated mounting bracket; 2-61. Strip hole; 3. Drive module; 3-1. Electric drive axle; 3-2. Rear brake; 3-3. Second integrated mounting bracket; 3-4. Second outer cover. Detailed Implementation

[0027] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0028] The purpose of this invention is to provide a modular solid chassis for commercial vehicles and an assembly method to solve the problems existing in the prior art. The solid chassis is modularly designed, and the assembly between modules can be completed in the final assembly workshop.

[0029] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0030] like Figures 1-8 As shown, a modular solid-state chassis for commercial vehicles is provided, including: a steering module 1, a drive module 3, and an energy storage module 2. The steering module 1 includes a first integrated mounting bracket 1-8, and components such as a steering gear 1-1, a motor cooler 1-2, a steering axle 1-3, a front brake 1-4, a front overhang beam, a front suspension 1-5, and a 24V power supply 1-7 mounted on the first integrated mounting bracket 1-8; the drive module 3 includes a second integrated mounting bracket 3-3, and components such as an electric drive axle 3-1 and a rear brake 3-2 mounted on the second integrated mounting bracket 3-3; the energy storage module 2 includes... It includes a third integrated mounting bracket 2-6, and components such as a battery pack 2-1, a battery cooling system 2-2, a high-voltage controller 2-4, and an integrated controller 2-5 mounted on the third integrated mounting bracket 2-6. The third integrated mounting bracket 2-6 is detachably connected to the first integrated mounting bracket 1-8 and the second integrated mounting bracket 3-3, realizing a modular design for the solid-state chassis. In the final assembly workshop, only the three modules need to be installed on the vehicle frame. The modular design can solve the problems that exist when the assembly and production of chassis parts are all concentrated in the final assembly workshop.

[0031] To improve modularity, a first outer cover 1-6 is wrapped around the outer periphery of the first integrated mounting bracket 1-8, and a second outer cover 3-4 is wrapped around the outer periphery of the second integrated mounting bracket 3-3. Both the first outer cover 1-6 and the second outer cover 3-4 are U-shaped. The U-shaped openings of the first outer cover 1-6 and the second outer cover 3-4 are both oriented towards the third integrated mounting bracket 2-6, that is, the first outer cover 1-6 and the second outer cover 3-4 are integrated into the modular design.

[0032] The third integrated mounting bracket 2-6 is equipped with side skirts 2-3 on both sides of the vehicle body to cooperate with the first outer cover 1-6 and the second outer cover 3-4 to form circumferential protection for the overall solid chassis.

[0033] In one embodiment, the side skirt guard plate 2-3 includes a fixed plate 2-31 and a sliding telescopic plate 2-32. The fixed plate 2-31 is fixedly connected to the third integrated mounting bracket 2-6, and the sliding telescopic plate 2-32 is slidably connected to the fixed plate 2-31. The sliding direction of the sliding telescopic plate 2-32 is parallel to the length direction of the vehicle body. The length of the entire side skirt guard plate 2-3 can be adjusted by adjusting the sliding of the sliding telescopic plate 2-32 to adapt to different lengths of vehicle frames in conjunction with the first outer cover 1-6 and the second outer cover 3-4.

[0034] The structure in which the fixed plate 2-31 and the sliding telescopic plate 2-32 are slidably connected can be as follows: a sliding groove is provided on the fixed plate 2-31 or the sliding telescopic plate 2-32, the sliding groove is parallel to the length direction of the vehicle body, and a slide rail or slider is provided on the sliding telescopic plate 2-32 or the fixed plate 2-31, the slide rail or slider is slidably engaged with the sliding groove, and the sliding is improved by the cooperation of the sliding groove and the slide rail or slider, thereby improving the ease of adjusting the length of the side skirt guard plate 2-3.

[0035] The sliding groove can be set as a dovetail groove, and the slide rail or slider matches the dovetail groove to prevent the fixed plate 2-31 from separating from the sliding telescopic plate 2-32 along the width direction of the vehicle body.

[0036] Multiple positioning holes can be made along the length of the sliding groove, and threaded holes can be provided on the slide rail or slider. When the fixed plate 2-31 and the sliding telescopic plate 2-32 are adjusted to the required length, a screw can be used to pass through a positioning hole and connect to the threaded hole to achieve positioning of the fixed plate 2-31 and the sliding telescopic plate 2-32; of course, a positioning pin or other structure can also be used to replace the screw.

[0037] The sliding groove can be a groove machined directly on the fixed plate 2-31 or the sliding telescopic plate 2-32, or a sliding channel steel 2-33 can be provided on the fixed plate 2-31 or the sliding telescopic plate 2-32. The inner cavity of the sliding channel steel 2-33 can be used as a sliding groove, which can effectively improve the service life.

[0038] When sliding channel steel 2-33 is used to form the sliding groove, an embedding block 2-36 is provided at one end of the positioning channel steel near the fixed plate 2-31 or the sliding telescopic plate 2-32. A groove is made on the fixed plate 2-31 or the sliding telescopic plate 2-32 at the position corresponding to the embedding block 2-36. The embedding block 2-36 is embedded in the groove. Then, the connection between the sliding channel steel 2-33 and the fixed plate 2-31 or the sliding telescopic plate 2-32 is completed by bolts or welding, which can improve the connection strength between the two. A reinforcing bracket 2-34 and / or a vertical reinforcing rib 2-35 are provided between the fixed plate 2-31 or the sliding telescopic plate 2-32 and the sliding channel steel 2-33. The reinforcing bracket 2-34 and the vertical reinforcing rib 2-35 both achieve structural reinforcement by connecting the fixed plate 2-31 or the sliding telescopic plate 2-32 and the sliding channel steel 2-33. When the reinforcing bracket 2-34 and the vertical reinforcing rib 2-35 exist alone, they can be set on either side of the width direction of the sliding channel steel 2-33. When both exist at the same time, they can be set on both sides of the width direction of the sliding channel steel 2-33 respectively.

[0039] Multiple sliding channel steels 2-33 can be sequentially installed from top to bottom on the fixed plate 2-31 or the sliding telescopic plate 2-32, along with multiple slide rails or multiple sliders, to further improve the overall structural strength.

[0040] The structure for the sliding connection between the fixed plate 2-31 and the sliding telescopic plate 2-32 can be as follows: a sliding cylinder and a sliding rod. A sliding cylinder is provided on the fixed plate 2-31 or the sliding telescopic plate 2-32 along the length of the vehicle body, and a corresponding sliding rod is provided on the sliding telescopic plate 2-32 or the fixed plate 2-31. The sliding rod is slidably set inside the sliding cylinder to realize the sliding connection between the fixed plate 2-31 and the sliding telescopic plate 2-32. The principle is the same as the cooperation method between the sliding groove and the slide rail or the slider. Of course, other structures that can realize the sliding connection between the fixed plate 2-31 and the sliding telescopic plate 2-32 can also be selected, as long as the sliding telescopic plate 2-32 can slide relative to the fixed plate 2-31.

[0041] In one embodiment, the two ends of the side skirt guard plate 2-3 are respectively located inside the first outer cover 1-6 and the second outer cover 3-4 to improve the continuity and aesthetics of the overall circumferential protection.

[0042] In one embodiment, the three integrated mounting brackets are connected as follows: the third integrated mounting bracket 2-6 is provided with at least one strip hole 2-61, which is parallel to the length direction of the vehicle body; the first integrated mounting bracket 1-8 and the second integrated mounting bracket 3-3 are each provided with multiple through holes; the connecting screw passes through the strip hole 2-61 and the through holes and is connected to the nut. The design of the strip hole 2-61 not only enables the connection of the third integrated mounting bracket 2-6 with the other two integrated mounting brackets, but also allows the position of the third integrated mounting bracket 2-6 to be adjusted by loosening the screw, thus improving the ease of operation.

[0043] Both the first integrated mounting bracket 1-8 and the second integrated mounting bracket 3-3 are provided with fixing holes for bolt connection and fixation to the vehicle frame.

[0044] The present invention also provides an assembly method for the above-mentioned modular solid chassis for commercial vehicles, comprising the following steps: S1: Connect the steering module 1 and the drive module 3 to the frame. Adjust the position of the steering module 1 and the drive module 3 by sliding them. After the relationship between the two modules and the frame is determined, fix them to the frame. S2: Insert the energy storage module 2 into the frame from the bottom and position it between the steering module 1 and the drive module 3; S3: Adjust the position of the energy storage module 2 between the front and rear modules by sliding. The adjustment is complete when the position of the energy storage module 2 meets the functional connection (such as lines, pipelines, etc.) with the front and rear modules. After the adjustment is completed, connect the third integrated mounting bracket 2-6 to the first integrated mounting bracket 1-8 and the second integrated mounting bracket 3-3 respectively.

[0045] After the positions of the three modules are fixed, adjust the sliding telescopic plate 2-32 so that the two ends of the overall side skirt guard plate 2-3 are respectively hidden inside the first outer cover 1-6 and the second outer cover 3-4.

[0046] Any adaptive changes made according to actual needs are within the scope of protection of this invention.

[0047] It should be noted that, for those skilled in the art, it is obvious that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0048] Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. Furthermore, those skilled in the art will recognize that, based on the ideas of this invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. A modular solid chassis for commercial vehicles, characterized in that, include: The steering module includes a first integrated mounting bracket, and a steering gear, motor cooler, steering axle, front brake, front overhang beam, front suspension and 24V power supply mounted on the first integrated mounting bracket; The drive module includes a second integrated mounting bracket, an electric drive axle mounted on the second integrated mounting bracket, and a rear brake; An energy storage module, comprising a third integrated mounting bracket, and a battery pack, a battery cooling system, a high-voltage controller, and an integrated controller mounted on the third integrated mounting bracket, wherein the third integrated mounting bracket is detachably connected to the first integrated mounting bracket and the second integrated mounting bracket respectively.

2. The modular solid chassis for commercial vehicles according to claim 1, characterized in that, The first integrated mounting bracket is covered by a first outer cover, and the second integrated mounting bracket is covered by a second outer cover. Both the first and second outer covers are U-shaped, and the U-shaped openings of the first and second outer covers are oriented towards the third integrated mounting bracket.

3. The modular solid chassis for commercial vehicles according to claim 2, characterized in that, The third integrated mounting bracket is equipped with side skirts on both sides of the vehicle body.

4. The modular solid chassis for commercial vehicles according to claim 3, characterized in that, The side skirt guard plate includes a fixed plate and a sliding telescopic plate. The fixed plate is fixedly connected to the third integrated mounting bracket, and the sliding telescopic plate is slidably connected to the fixed plate. The sliding direction of the sliding telescopic plate is parallel to the length direction of the vehicle body.

5. The modular solid chassis for commercial vehicles according to claim 4, characterized in that, The fixed plate or the sliding telescopic plate is provided with a sliding groove, which is parallel to the length direction of the vehicle body. The sliding telescopic plate or the fixed plate is provided with a slide rail or a slider, which slides in cooperation with the sliding groove.

6. The modular solid chassis for commercial vehicles according to claim 5, characterized in that, The fixed plate or the sliding telescopic plate is provided with a sliding channel steel, and the inner cavity of the sliding channel steel is the sliding groove.

7. The modular solid chassis for commercial vehicles according to claim 6, characterized in that, A reinforcing bracket and / or vertical reinforcing ribs are provided between the fixed plate or the sliding telescopic plate and the sliding channel steel.

8. The modular solid chassis for commercial vehicles according to claim 3, characterized in that, The two ends of the side skirt guard are located inside the first outer cover and the second outer cover, respectively.

9. The modular solid chassis for commercial vehicles according to claim 1, characterized in that, The third integrated mounting bracket is provided with at least one strip hole, which is parallel to the length direction of the vehicle body. The first integrated mounting bracket and the second integrated mounting bracket are both provided with multiple through holes. The connecting screw passes through the strip hole and the through holes and is connected to the nut.

10. An assembly method, characterized in that, The application to the modular solid chassis for commercial vehicles according to any one of claims 1-9 includes the following steps: S1: Connect the steering module and drive module to the frame, and after adjusting the positions of the steering module and drive module, fix them to the frame; S2: Insert the energy storage module into the frame from the bottom and position it between the steering module and the drive module; S3: Adjust the position of the energy storage module. After adjustment, connect the third integrated mounting bracket to the first integrated mounting bracket and the second integrated mounting bracket respectively.

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