Modular assembly and integral welding type high-strength aluminum house car bearing box and manufacturing process

Abstract

The application relates to the technical field of motor home body structure manufacturing, in particular to a modular assembly and integrated welding type high-strength aluminum motor home carrying box body and a manufacturing process, the box body comprising a carrying frame, the carrying frame comprising a bottom carrying assembly, an end wall column assembly, a top cover assembly and a side wall assembly, the bottom carrying assembly, the end wall column assembly, the top cover assembly and the side wall assembly being integrally welded and formed, the bottom carrying assembly, the end wall column assembly, the top cover assembly and the side wall assembly being made of high-strength aluminum alloy extruded profiles, adopting an integrated welding type structure, without bolt loosening and glue aging problems, the overall torsional strength and carrying capacity being better than those of a traditional spliced box body, box body deformation, cracking and falling off under complex road conditions being effectively avoided, and motor home driving safety being greatly improved, 6005A-T6 rail transit aluminum alloy extruded profiles being adopted, the density being low and the strength being high, the overall box body self weight being smaller than the mass of a steel box body, and the energy consumption of the whole vehicle being reduced.

Description

Technical Field

[0001] This invention relates to the technical field of RV body structure manufacturing, and in particular to modular assembly and integrated welded high-strength aluminum RV load-bearing box and its manufacturing process. Background Technology

[0002] Currently, most mainstream RV cargo boxes on the market use steel frames and sheet metal splicing or aluminum profile bolt assembly and bonding structures, which have many technical defects.

[0003] First, the steel box body is extremely heavy, increasing the overall vehicle load, which leads to higher fuel and electricity consumption, poorer driving performance, and the steel is prone to rust and corrosion, resulting in a short service life.

[0004] Secondly, traditional aluminum enclosures are mostly assembled by bolting and bonding segmented profiles, resulting in many gaps. Over time, the bumps and twisting of the vehicle body can easily cause bolts to loosen and the adhesive to age and crack. This not only results in insufficient load-bearing strength and torsional rigidity of the enclosure, significantly reducing the safety of RV driving, but also makes it very easy for rainwater to leak, causing mold inside the enclosure, damage to the interior, and corrosion of the frame.

[0005] Furthermore, the existing modular box-type structures lack an overall load-bearing structure, resulting in concentrated stress in certain areas. Under off-road conditions, the frame is prone to deformation and the panels may fall off, making them unsuitable for long-term use in complex road conditions.

[0006] In existing technologies, some aluminum RV bodies are connected by simple spot welding, resulting in discontinuous welds, poor sealing, and weak load-bearing capacity. This fails to achieve a balanced overall load-bearing effect, making it difficult to simultaneously achieve lightweight design and high strength, and thus failing to meet the usage standards for high-end recreational, off-road, and special-purpose RVs. Therefore, it is necessary to develop a one-piece welded, high-strength, fully enclosed, and lightweight aluminum alloy RV load-bearing body structure to overcome the many shortcomings of existing technologies. Summary of the Invention

[0007] To solve the above-mentioned technical problems, the present invention provides a modular assembly and integrated welded high-strength aluminum RV load-bearing box and its manufacturing process.

[0008] The modular assembly and integrated welded high-strength aluminum RV load-bearing box of the present invention includes a load-bearing frame, wherein the load-bearing frame includes a bottom load-bearing assembly, an end wall column assembly, a top cover assembly and a side wall assembly, wherein the bottom load-bearing assembly, the end wall column assembly, the top cover assembly and the side wall assembly are integrally welded, and wherein the bottom load-bearing assembly, the end wall column assembly, the top cover assembly and the side wall assembly are made of high-strength aluminum alloy extruded profiles; The bottom load-bearing assembly includes longitudinal side beams, load-bearing aluminum profile beams, and floor profiles. The longitudinal side beams, load-bearing aluminum profile beams, and floor profiles are automatically welded together by a robot, forming a high-density grid load-bearing structure. The end wall column assembly includes four main columns; The top cover assembly and the bottom load-bearing assembly have the same structure; The bottom load-bearing assembly, end wall column assembly, top cover assembly, and side wall assembly are reinforced with diagonal ribs.

[0009] Preferably, the bottom load-bearing assembly is made of 60mm thick hollow rectangular high-strength aluminum profile. Two longitudinal side beams and two load-bearing aluminum profile crossbeams are provided. The longitudinal side beams, load-bearing aluminum profile crossbeams and floor profiles are continuously and fully welded at the staggered positions to form a closed bottom load-bearing assembly.

[0010] Preferably, the main column is made of L-shaped high-strength aluminum alloy profile, the height of the main column is matched with the total height of the box, the upper end of the main column is fully welded to the top cover assembly, and the lower end of the main column is fully welded to the bottom load-bearing assembly.

[0011] Preferably, the top cover assembly is made of 30mm thick hollow rectangular high-strength aluminum profile, and the top cover assembly also includes two longitudinal beams, two end beams and a top plate profile, and the two longitudinal beams, two end beams and the top plate profile are continuously and fully welded and sealed.

[0012] Preferably, the side wall assembly is integrally welded from side wall panel profiles, the side wall panel profiles are composed of three types of profiles, the side wall assembly is provided with windows, doorways and air conditioning vents, and the side wall assembly requires post-processing after welding.

[0013] Preferably, after the bearing frame is welded, it is adjusted to ensure the flatness of the outer side, the bearing frame is sandblasted as a whole, and the surface of the bearing frame is sprayed with anti-corrosion and weather-resistant paint.

[0014] This invention also provides a manufacturing process for a modular assembly and integrated welded high-strength aluminum RV load-bearing box, comprising the following steps: Step 1: Hoist the bottom load-bearing assembly and fix each component of the bottom load-bearing assembly on the assembly platform; Step 2: Hoist the end wall column assembly. Hoist the end wall column assembly onto the top of the bottom bearing assembly and fit it snugly with the main column. Then, install diagonal braces between the bottom bearing assembly and the end wall column assembly and perform positioning spot welding at the connection. Step 3: Hoist the side wall assembly. Hoist and fix the side wall assembly between the two main columns, and adjust the height of the side wall assembly. After the side wall assembly is adjusted, install the diagonal brace and upper wide brace at the set position. Step 4: Hoist the top cover assembly. Hoist the top cover assembly onto the upper part of the side wall assembly and the end wall column assembly. Adjust the upper width dimension to ensure that the edges of the side wall assembly and the top cover assembly overlap and fit together. The misalignment of the outer side of the weld should be ≤1mm. After the top cover assembly is hoisted, install the height support rod inside to adjust the height of the box and the size of the installation opening. After the height adjustment is completed, perform tack welding on the inner and outer welds of the box.

[0015] Preferably, the anti-deformation amount is pre-formed at different positions of each component, and welding is carried out from the inside out and from the middle to both sides, while controlling the amount of deformation during assembly welding.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows: Adopting an integrated welded structure, it eliminates issues such as loose bolts and aging of adhesives. Its overall torsional strength and load-bearing capacity are superior to traditional spliced ​​boxes, effectively preventing deformation, cracking, and detachment of the box under complex road conditions, and significantly improving the safety of RV driving.

[0017] It adopts 6005A-T6 rail transit aluminum alloy extrusion profile, which has low density and high strength. The overall body weight is smaller than that of steel body, which reduces the energy consumption of the whole vehicle, improves the vehicle's passability, and at the same time ensures that the load-bearing performance meets the needs of travel and special operations.

[0018] All seams are fully welded and sealed, eliminating any leakage gaps and solving the common problem of water leakage in traditional enclosures. The dual anti-corrosion treatment process makes it suitable for humid and complex outdoor environments. The aluminum profile itself has excellent anti-oxidation and corrosion resistance, extending the service life of the enclosure.

[0019] The bottom load-bearing assembly, end wall column assembly, roof assembly, and side wall assembly are designed as a whole, which ensures uniform stress distribution, resistance to bumps and torsion, making it suitable for everyday road travel RVs as well as high-intensity use scenarios such as off-road crossings and special outdoor operations, with strong versatility.

[0020] Modularly integrated welding ensures high dimensional accuracy and overall integrity of the box body, with rounded corners for enhanced safety. It can also be directly integrated with the RV chassis for assembly, simplifying the production process and reducing assembly errors. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a structural schematic diagram from another perspective of the present invention; Figure 3 This is a top view cross-sectional structural diagram of the present invention; Figure 4 This is the invention Figure 3 A magnified schematic diagram of the partial structure at point A in the middle; Figure 5 This is a side view cross-sectional structural schematic diagram of the present invention; Figure 6 This is the invention Figure 5 A magnified schematic diagram of the local structure at point B; Figure 7 This is the invention Figure 5 A magnified schematic diagram of the structure at point C.

[0022] Reference numerals: 1. Bottom load-bearing assembly; 2. End wall column assembly; 3. Top cover assembly; 4. Side wall assembly; 101. Longitudinal edge beam; 102. Load-bearing aluminum profile beam; 103. Floor profile; 201. Main column. Detailed Implementation

[0023] To facilitate understanding of the present invention, a more complete description will be given below with reference to the accompanying drawings. The present invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete.

[0024] like Figures 1 to 7 As shown, this invention discloses a modular assembly and integrated welded high-strength aluminum RV load-bearing box and its manufacturing process, including a load-bearing frame. The load-bearing frame includes a bottom load-bearing assembly 1, an end wall column assembly 2, a top cover assembly 3, and a side wall assembly 4. The bottom load-bearing assembly 1, the end wall column assembly 2, the top cover assembly 3, and the side wall assembly 4 are integrally welded. The bottom load-bearing assembly 1, the end wall column assembly 2, the top cover assembly 3, and the side wall assembly 4 are made of high-strength aluminum alloy extruded profiles. The entire vehicle box adopts a non-disassembly splicing structure. All profile splicing welds adopt a full welding sealing process to achieve integrated load-bearing and fully sealed waterproof and corrosion-resistant effects. The profiles are selected from 6005A-T6 high-strength aluminum alloy extruded profiles.

[0025] The bottom load-bearing assembly 1 includes longitudinal side beams 101, load-bearing aluminum profile crossbeams 102, and floor profiles 103. The longitudinal side beams 101, load-bearing aluminum profile crossbeams 102, and floor profiles 103 are automatically welded together by a robot. The longitudinal side beams 101, load-bearing aluminum profile crossbeams 102, and floor profiles 103 form a high-density grid load-bearing structure. By automatically welding together by a robot, the whole structure forms a high-density grid load-bearing structure, which can effectively distribute the stress on the whole vehicle and improve the compressive and deformation resistance of the bottom of the vehicle body.

[0026] The end wall column assembly 2 includes four main columns 201. A middle end wall plate is set between two main columns 201 with short spacing. The main columns 201 at the four corners form the core vertical support of the box, ensuring the overall verticality and structural rigidity of the box, and working with the side wall assembly 4 to achieve overall side protection and load-bearing.

[0027] The top cover assembly 3 has the same structure as the bottom load-bearing assembly 1. It is formed by welding an overall enclosed aluminum profile and is equipped with longitudinal beams and end beams to improve the top's resistance to wind pressure and collapse. The aluminum profile of the top cover assembly 3 is also fully sealed by robotic automatic welding to eliminate the risk of water leakage at the top.

[0028] The bottom load-bearing assembly 1, end wall column assembly 2, top cover assembly 3 and side wall assembly 4 are reinforced with diagonal ribs, forming multiple stable triangular support structures inside the box, which greatly improves the box's torsional resistance and makes it suitable for bumpy off-road conditions.

[0029] The bottom load-bearing assembly 1 is made of 60mm thick hollow rectangular high-strength aluminum profile. There are two longitudinal side beams 101 and two load-bearing aluminum profile crossbeams 102. The longitudinal side beams 101, load-bearing aluminum profile crossbeams 102 and floor profiles 103 are continuously and fully welded at the intersection to form a closed bottom load-bearing assembly 1. The flatness of the bottom load-bearing assembly 1 is 2mm / 2m.

[0030] The main column 201 is made of L-shaped high-strength aluminum alloy profile. The height of the main column 201 matches the total height of the box. The upper end of the main column 201 is fully welded to the top cover assembly 3, and the lower end of the main column 201 is fully welded to the bottom bearing assembly 1. The vertical error of the four main columns 201 is ≤1mm.

[0031] The top cover assembly 3 uses 30mm thick hollow rectangular high-strength aluminum profile. The top cover assembly 3 also includes two longitudinal beams, two end beams and a top plate profile. The two longitudinal beams, two end beams and the top plate profile are continuously and fully welded and sealed. During the welding process, the weld is required to be flat, without pores or cracks.

[0032] The side wall assembly 4 is integrally welded from the side wall panel profile. The side wall panel profile consists of three types of profiles. The side wall assembly 4 is equipped with windows, doors and air conditioning vents. After welding, the side wall assembly 4 needs to be post-processed, specifically by grinding and polishing to ensure that the side wall assembly 4 is free of protrusions and gaps.

[0033] After the load-bearing frame is welded, adjustments are made to ensure the flatness of the outer side. The entire load-bearing frame is then sandblasted, and the surface of the load-bearing frame is coated with anti-corrosion and weather-resistant paint. By spraying the surface with anti-corrosion and weather-resistant paint, the service life of the load-bearing frame is enhanced and the occurrence of rust is reduced.

[0034] In the manufacturing process of this invention, 6005A-T6 high-strength aluminum alloy extruded profiles for rail transit are selected as the base material, and 60mm thick hollow rectangular high-strength aluminum profiles are used as the main material. Specifically, the structure consists of two longitudinal side beams 101 of model MTXC-396, two load-bearing aluminum profile crossbeams 102 of model MTXC-396, and floor profiles 103, wherein the floor profiles 103 are model BZDTA-XC-DJ-006, BZDTA-XC-DJ-007 and 0B747549. The above materials are arranged vertically and alternately to form a high-density network structure. The contact parts of all components are continuously and fully welded by robotic automatic welding technology to form a closed bottom load-bearing assembly 1. After welding, the flatness error of the bottom load-bearing assembly 1 is controlled within 2mm / 2m to ensure the stability of the overall assembly.

[0035] L-shaped high-strength aluminum alloy columns 201 are set at the four corners of the enclosure. Their height matches the total height of the enclosure design. The four main columns 201 serve as the core vertical support of the enclosure. End wall plates are set between two main columns 201 with short spacing to form a seal.

[0036] The two main columns, with a 201-meter spacing, form a side wall assembly 4 made of three types of double-layer hollow aluminum alloy profiles. The three profiles are model 8N8T-XC-DP-005, 8N8T-XC-DP-006, and 8N8T-XC-DP-007. The three profiles are welded together to form the side wall assembly 4. During the welding process, the welding sequence is to weld the outer weld first, and then weld the inner weld. The long profiles adopt a continuous structure, and the profiles are not cut at the corresponding locations of the windows and doors. After welding, the flatness is measured by flame adjustment and using a 2m straightedge. After overall adjustment, the windows, doors, and air conditioning vents are machined.

[0037] When manufacturing the top cover assembly 3, 30mm thick hollow rectangular high-strength aluminum alloy profiles are used as the main material. Specifically, there are two longitudinal beams, two end beams, and a top plate profile. The longitudinal beam model is MTXC-395, and the top plate profile models are 8N8T-XC-DP-005, 8N8T-XC-DP-006, and 8N8T-XC-DP-007. The top cover assembly 3 is similar in structure to the bottom load-bearing assembly 1, and adopts an enclosed design. The joints of each profile are continuously and fully welded and sealed by robotic automatic welding, and the flatness of the weld is controlled to ensure that there are no pores or cracks.

[0038] After the above fabrication is completed, proceed with the final assembly welding of the enclosure according to the following steps: Step 1: Hoist the bottom load-bearing assembly 1 and fix each component of the bottom load-bearing assembly 1 on the assembly platform.

[0039] Step 2: Hoist the end wall column assembly 2. Hoist the end wall column assembly 2 onto the upper end of the bottom bearing assembly 1, and fit the bottom bearing assembly 1 with the main column 201. Then, install diagonal bracing between the bottom bearing assembly 1 and the end wall column assembly 2, and perform positioning spot welding at the connection to ensure that the misalignment of the fitting gap between the end wall column assembly 2 and the bottom bearing assembly 1 is ≤1mm.

[0040] Step 3: Hoist the side wall assembly 4 and fix it between the two main columns 201. Adjust the height of the side wall assembly 4. After the side wall assembly 4 is adjusted, install the diagonal brace and the upper wide brace in the set position.

[0041] Step 4: Hoist the top cover assembly 3. Hoist the top cover assembly 3 onto the upper end of the side wall assembly 4 and the end wall column assembly 2. Adjust the upper width dimension so that the edges of the side wall assembly 4 and the top cover assembly 3 overlap and fit together. The misalignment of the outer side of the weld should be ≤1mm. After the top cover assembly 3 is hoisted, install the height support rod inside to adjust the height of the box and the size of the installation opening. After the height adjustment is completed, perform tack welding on the inner and outer welds of the box.

[0042] Step 5: Pre-deform the deformation at different locations of each component, and weld from the inside out and from the middle to both sides, while controlling the amount of deformation during assembly welding.

[0043] Step Six: Post-welding treatment. After the overall box body is welded, a comprehensive adjustment is carried out to ensure that the flatness of the outer side of the box body and all dimensions meet the design requirements. At the same time, residual internal stress from welding is eliminated. After the adjustment is completed, the entire box body is sandblasted to remove the surface oxide layer and roughen the surface. After sandblasting, a special anti-corrosion and weather-resistant paint for RVs is sprayed on the surface of the box body to complete the final anti-corrosion treatment and form the finished box body.

[0044] The main functions achieved by this invention are: adopting an integrated welded structure, eliminating problems such as loose bolts and aging of adhesives, and having better overall torsional strength and load-bearing capacity than traditional spliced ​​boxes, effectively avoiding deformation, cracking, and detachment of the box under complex road conditions, and greatly improving the driving safety of the RV.

[0045] It adopts 6005A-T6 rail transit aluminum alloy extrusion profile, which has low density and high strength. The overall body weight is smaller than that of steel body, which reduces the energy consumption of the whole vehicle, improves the vehicle's passability, and at the same time ensures that the load-bearing performance meets the needs of travel and special operations.

[0046] All seams are fully welded and sealed, eliminating any leakage gaps and solving the common problem of water leakage in traditional enclosures. The dual anti-corrosion treatment process makes it suitable for humid and complex outdoor environments. The aluminum profile itself has excellent anti-oxidation and corrosion resistance, extending the service life of the enclosure.

[0047] The bottom load-bearing assembly 1, end wall column assembly 2, top cover assembly 3, and side wall assembly 4 are designed as a whole, which ensures uniform stress distribution, resistance to bumps and torsion, and is suitable for everyday road travel RVs as well as high-intensity use scenarios such as off-road crossings and special outdoor operations, making it highly versatile.

[0048] Modularly integrated welding ensures high dimensional accuracy and overall integrity of the box body, with rounded corners for enhanced safety. It can also be directly integrated with the RV chassis for assembly, simplifying the production process and reducing assembly errors.

[0049] The modular assembly and integrated welded high-strength aluminum RV load-bearing box of the present invention can be installed, connected or set up in a common mechanical way, and can be implemented as long as it can achieve its beneficial effect.

[0050] All technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the specification of this invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0051] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A modular assembly and integrated welded high-strength aluminum RV load-bearing box, characterized in that, The system includes a load-bearing frame, which comprises a bottom load-bearing assembly (1), an end wall column assembly (2), a top cover assembly (3), and a side wall assembly (4). The bottom load-bearing assembly (1), the end wall column assembly (2), the top cover assembly (3), and the side wall assembly (4) are integrally welded together. The bottom load-bearing assembly (1), the end wall column assembly (2), the top cover assembly (3), and the side wall assembly (4) are made of high-strength aluminum alloy extruded profiles. The bottom load-bearing assembly (1) includes longitudinal side beams (101), load-bearing aluminum profile crossbeams (102), and floor profiles (103). The longitudinal side beams (101), load-bearing aluminum profile crossbeams (102), and floor profiles (103) are automatically welded by a robot. The longitudinal side beams (101), load-bearing aluminum profile crossbeams (102), and floor profiles (103) form a high-density grid load-bearing structure. The end wall column assembly (2) includes four main columns (201); The top cover assembly (3) has the same structure as the bottom load-bearing assembly (1); The bottom bearing assembly (1), end wall column assembly (2), top cover assembly (3) and side wall assembly (4) are reinforced with diagonal ribs.

2. The modular assembly and integrated welded high-strength aluminum RV load-bearing box as described in claim 1, characterized in that, The bottom load-bearing assembly (1) is made of 60mm thick hollow rectangular high-strength aluminum profile. Two longitudinal side beams (101) and two load-bearing aluminum profile crossbeams (102) are provided. The longitudinal side beams (101), the load-bearing aluminum profile crossbeams (102) and the floor profiles (103) are continuously and fully welded at staggered positions to form a closed bottom load-bearing assembly (1).

3. The modular assembly and integrated welded high-strength aluminum RV load-bearing box as described in claim 1, characterized in that, The main column (201) is made of L-shaped high-strength aluminum alloy profile. The height of the main column (201) matches the total height of the box. The upper end of the main column (201) is fully welded to the top cover assembly (3), and the lower end of the main column (201) is fully welded to the bottom bearing assembly (1).

4. The modular assembly and integrated welded high-strength aluminum RV load-bearing box as described in claim 1, characterized in that, The top cover assembly (3) is made of 30mm thick hollow rectangular high-strength aluminum profile. The top cover assembly (3) also includes two longitudinal beams, two end beams and a top plate profile. The two longitudinal beams, two end beams and the top plate profile are continuously and fully welded and sealed.

5. The modular assembly and integrated welded high-strength aluminum RV load-bearing box as described in claim 1, characterized in that, The side wall assembly (4) is integrally welded from side wall panel profiles. The side wall panel profiles are composed of three types of profiles. The side wall assembly (4) is provided with windows, doors and air conditioning vents. The side wall assembly (4) needs to be post-processed after welding.

6. The modular assembly and integrated welded high-strength aluminum RV load-bearing box as described in claim 1, characterized in that, After the load-bearing frame is welded, it is adjusted to ensure the flatness of the outer side. The entire load-bearing frame is sandblasted and coated with anti-corrosion and weather-resistant paint.

7. A manufacturing process for a modular assembly and integrated welded high-strength aluminum RV load-bearing box as described in claim 1, characterized in that, Includes the following steps: Step 1: Hoist the bottom load-bearing assembly (1) and fix each component of the bottom load-bearing assembly (1) on the assembly platform; Step 2: Hoist the end wall column assembly (2). Hoist the end wall column assembly (2) onto the upper end of the bottom bearing assembly (1) and fit the bottom bearing assembly (1) with the main column (201). Then install the diagonal brace between the bottom bearing assembly (1) and the end wall column assembly (2) and spot weld the connection. Step 3: Hoist the side wall assembly (4), hoist and fix the side wall assembly (4) between the two main columns (201), and adjust the height of the side wall assembly (4). After the side wall assembly (4) is adjusted, install the diagonal brace and upper wide brace at the set position. Step 4: Hoist the top cover assembly (3). Hoist the top cover assembly (3) onto the upper end of the side wall assembly (4) and the end wall column assembly (2). Adjust the upper width dimension so that the edges of the side wall assembly (4) and the top cover assembly (3) overlap and fit together. The misalignment of the outer side of the weld should be ≤1mm. After the top cover assembly (3) is hoisted, install the height support rod inside to adjust the height of the box and the size of the installation opening. After the height adjustment is completed, perform positioning welding on the inner and outer welds of the box.

8. The manufacturing process of the modular assembly and integrated welded high-strength aluminum RV load-bearing box as described in claim 7, characterized in that, Pre-deformation amounts are applied to different locations of each component. Welding is performed from the inside out and from the middle to both sides, and the amount of deformation during assembly welding is controlled.

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