Frame assembly, vehicle chassis structure and electric vehicle

Abstract

The utility model provides a frame assembly, a vehicle chassis structure and an electric vehicle, and relates to the technical field of new energy vehicles. A left longitudinal beam and a right longitudinal beam in the frame assembly are arranged in the preset longitudinal extending direction, and a first via hole cross beam assembly, a second via hole cross beam assembly, a cast balance shaft cross beam and a tail beam are sequentially arranged between the left longitudinal beam and the right longitudinal beam. Each of the left longitudinal beam and the right longitudinal beam comprises a first uniform section, a variable section and a second uniform section, the first via hole cross beam assembly is arranged between the first uniform section of the left longitudinal beam and the first uniform section of the right longitudinal beam, the second via hole cross beam assembly is arranged between the variable section of the left longitudinal beam and the variable section of the right longitudinal beam, and the cast balance shaft cross beam and the tail beam are sequentially arranged between the second uniform section of the left longitudinal beam and the second uniform section of the right longitudinal beam; a battery system is arranged in a preset layout area between the first via hole beam assembly and the second via hole beam assembly. The convenience of hoisting operation of the battery system is improved, space is provided for pipeline layout, the strength of the frame assembly is enhanced, and the driving safety and stability of the electric vehicle are improved.

Description

Chassis assembly, vehicle chassis structure and electric vehicles Technical Field

[0001] This application relates to the field of new energy vehicle technology, specifically to a vehicle frame assembly, a vehicle chassis structure, and an electric vehicle. Background Technology

[0002] With the rapid development of battery technology, the purchase cost of battery systems has been continuously decreasing, and energy density has been significantly improved. Simultaneously, the deployment of fast-charging, high-power charging equipment has become increasingly sophisticated, driving the rapid development of the pure electric heavy-duty truck industry. To enhance the range of pure electric heavy-duty trucks and seize the long-haul transportation market, they all adopt high-capacity battery systems of 600kWh+, which are installed in the vehicle chassis. However, the significant weight of the high-capacity battery system places higher demands on the chassis assembly. This chassis assembly must not only meet the installation requirements of the battery system but also possess sufficient load-bearing strength.

[0003] Currently, the width of the chassis assembly of mainstream pure electric heavy-duty trucks is 850mm, the width of the chassis assembly flange is 80mm, while the mainstream width of the battery system is 646mm. Due to this significant size difference, the distance between the battery system and the chassis assembly is only 22mm. This narrow gap makes lifting the battery system difficult and limits the layout of pipelines. Furthermore, the overall length of current large-capacity battery systems is 2265mm. Because the middle section of the chassis assembly is filled with the battery system, it is impossible to place crossbeams in the middle section of the chassis assembly. Moreover, due to the ground clearance limitations of electric vehicles, a basin beam structure (i.e., the lower middle section of the left and right longitudinal beams) cannot be used, resulting in insufficient strength in the chassis assembly and affecting the safety and stability of pure electric heavy-duty trucks. Summary of the Invention

[0004] In view of this, the purpose of this application is to provide a frame assembly, a vehicle chassis structure, and an electric vehicle to enhance the strength of the frame assembly of the mid-mounted battery system and improve the safety and stability of the electric vehicle during operation.

[0005] To achieve the above objectives, the technical solutions adopted in the embodiments of this application are as follows:

[0006] In a first aspect, embodiments of this application provide a vehicle frame assembly, the vehicle frame assembly including: a left longitudinal beam, a right longitudinal beam, a first through-hole crossbeam assembly, a second through-hole crossbeam assembly, a cast balance shaft crossbeam, and a rear beam; the left longitudinal beam and the right longitudinal beam are arranged opposite to each other along a predetermined longitudinal extension direction, and the first through-hole crossbeam assembly, the second through-hole crossbeam assembly, the cast balance shaft crossbeam, and the rear beam are sequentially fixed between the left longitudinal beam and the right longitudinal beam along the predetermined longitudinal extension direction;

[0007] The left longitudinal beam and the right longitudinal beam each include: a first equal cross-section segment, a variable cross-section segment and a second equal cross-section segment arranged sequentially in the preset longitudinal extension direction; the first through-hole cross-beam assembly is fixedly disposed between the first equal cross-section segment of the left longitudinal beam and the right longitudinal beam; the second through-hole cross-beam assembly is fixedly disposed between the variable cross-section segment of the left longitudinal beam and the right longitudinal beam; and the cast balance shaft cross-beam and the tail beam are sequentially fixedly disposed between the second equal cross-section segment of the left longitudinal beam and the right longitudinal beam.

[0008] The pre-defined layout area between the first through-hole beam assembly and the second through-hole beam assembly is used to fix the battery system.

[0009] Optionally, the first width between the left longitudinal beam and the right longitudinal beam in the first equal cross-section section is greater than the second width between the left longitudinal beam and the right longitudinal beam in the second equal cross-section section, and the width between the left longitudinal beam and the right longitudinal beam in the variable cross-section section is the width that varies from the first width to the second width along the preset longitudinal extension direction.

[0010] Optionally, the frame assembly further includes: an upward-folding crossbeam assembly, which is fixedly disposed between the first equal cross-section segments of the left longitudinal beam and the right longitudinal beam, and the upward-folding crossbeam assembly is located between the first through-hole crossbeam assembly and the second through-hole crossbeam in the preset longitudinal extension direction.

[0011] Optionally, the upward-turning crossbeam assembly includes: two connecting supports and an upward-turning crossbeam, the two connecting supports being fixedly connected to the left longitudinal beam and the right longitudinal beam respectively, and the two ends of the upward-turning crossbeam being fixedly connected to the two connecting supports respectively.

[0012] Optionally, the first through-hole beam assembly includes: two first upper connecting plates, two first lower connecting plates, and a first through-hole beam, wherein the side of the first through-hole beam has a through hole;

[0013] The two first upper connecting plates are respectively fixed to the two ends of the top surface of the first through-hole beam, and the two first lower connecting plates are respectively fixed to the two ends of the bottom surface of the first through-hole beam. The two first upper connecting plates are also respectively fixed to the top of the first equal cross-section section of the left longitudinal beam and the right longitudinal beam, and the two first lower connecting plates are also respectively fixed to the bottom of the first equal cross-section section of the left longitudinal beam and the right longitudinal beam.

[0014] Optionally, the end of the side of the first through-hole beam has a flared cut.

[0015] Optionally, the second through-hole beam assembly includes: two second upper connecting plates, two second lower connecting plates, and a second through-hole beam, wherein the side of the second through-hole beam has a through hole;

[0016] The two second upper connecting plates are respectively fixed to the two ends of the top surface of the second through-hole beam, and the two second lower connecting plates are respectively fixed to the two ends of the bottom surface of the first through-hole beam. The two second upper connecting plates are also respectively fixed to the top of the variable cross-section section of the left longitudinal beam and the right longitudinal beam, and the two second lower connecting plates are also respectively fixed to the bottom of the variable cross-section section of the left longitudinal beam and the right longitudinal beam.

[0017] Optionally, the end of the second through-hole beam has a flared notch.

[0018] Secondly, embodiments of this application provide a vehicle chassis structure, including at least: a frame assembly as described in any of the first aspects, and a battery system fixedly disposed in a predetermined layout area between a first through-hole crossbeam assembly and a second through-hole crossbeam assembly on the frame assembly.

[0019] Thirdly, embodiments of this application provide an electric vehicle, which includes at least the vehicle chassis structure described in the second aspect.

[0020] This application provides a frame assembly, a vehicle chassis structure, and an electric vehicle. The frame assembly comprises a left longitudinal beam, a right longitudinal beam, a first through-hole crossbeam assembly, a second through-hole crossbeam assembly, a cast balance shaft crossbeam, and a tail beam. The left and right longitudinal beams are arranged opposite each other along a predetermined longitudinal extension direction. The first through-hole crossbeam assembly, the second through-hole crossbeam assembly, the cast balance shaft crossbeam, and the tail beam are sequentially fixed between the left and right longitudinal beams along the predetermined longitudinal extension direction, thus forming a complete frame assembly. Both the left and right longitudinal beams are designed as segmented structures consisting of a first equal-section segment, a variable-section segment, and a second equal-section segment arranged sequentially along the predetermined longitudinal extension direction. The first through-hole crossbeam assembly is fixed between the first equal-section segments of the left and right longitudinal beams, the second through-hole crossbeam assembly is fixed between the variable-section segments of the left and right longitudinal beams, and the cast balance shaft crossbeam and the tail beam are sequentially fixed between the second equal-section segments of the left and right longitudinal beams. The predetermined layout area between the first and second through-hole crossbeam assemblies is used to fix the battery system. Therefore, the first through-hole crossbeam assembly and the second through-hole crossbeam assembly in this application are set at the starting point of the first equal cross-section section and the variable cross-section section, forming a stable frame structure. This structure evenly distributes the weight of the battery system installed in between across the entire length of the left and right longitudinal beams, avoiding the risk of deformation or fracture caused by local stress concentration. This enhances the strength of the frame assembly of the mid-mounted battery system, thereby improving the driving stability and safety of electric vehicles under complex operating conditions. Attached Figure Description

[0021] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 is a schematic diagram of a vehicle frame assembly provided in an embodiment of this application;

[0023] Figure 2 is a structural schematic diagram of a vehicle frame assembly provided in an embodiment of this application;

[0024] Figure 3 is a structural schematic diagram of a vehicle frame assembly provided in an embodiment of this application;

[0025] Figure 4 is a structural schematic diagram of an upward-turning crossbeam assembly provided in an embodiment of this application;

[0026] Figure 5 is a structural schematic diagram of a welding lap joint method for an upward-turning crossbeam provided in an embodiment of this application;

[0027] Figure 6 is a structural schematic diagram of a first through-hole beam assembly provided in an embodiment of this application;

[0028] Figure 7 is a schematic diagram of the side end structure of a first through-hole beam provided in an embodiment of this application;

[0029] Figure 8 is a side structural diagram of a second through-hole beam assembly and a first through-hole beam assembly provided in an embodiment of this application;

[0030] Figure 9 is a structural schematic diagram of a vehicle chassis structure provided in an embodiment of this application;

[0031] Figure 10 is a structural schematic diagram of an electric vehicle provided in an embodiment of this application. Detailed Implementation

[0032] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0033] Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0034] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0035] In the description of this application, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the utility model product is in use. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application. In addition, the terms "first," "second," and "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0036] Furthermore, terms such as "horizontal," "vertical," and "sag" do not imply that components must be absolutely horizontal or suspended, but rather that they can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal relative to "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0037] In the description of this application, it should also be noted that, unless otherwise expressly specified and limited, the terms "set up," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0038] The following detailed description of some embodiments of this application is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0039] To better understand the various solutions provided in the embodiments of this application, the following detailed description of a vehicle frame assembly, vehicle chassis structure, and electric vehicle provided in the embodiments of this application will be provided in conjunction with the accompanying drawings.

[0040] Figure 1 is a schematic diagram of a frame assembly provided in an embodiment of this application. As shown in Figure 1, the frame assembly 100 may include: a left longitudinal beam 110, a right longitudinal beam 120, a first through-hole crossbeam assembly 130, a second through-hole crossbeam assembly 140, a cast balance shaft crossbeam 150, and a rear beam 160.

[0041] The left longitudinal beam 110 and the right longitudinal beam 120 are arranged opposite each other along a predetermined longitudinal extension direction. These two beams are the main longitudinal load-bearing components of the frame assembly 100, forming the two side boundaries of the frame assembly 100. The predetermined longitudinal extension direction can be selected according to actual conditions. For example, it can refer to the longitudinal extension direction of the vehicle from the front to the rear. The materials of the left longitudinal beam 110 and the right longitudinal beam 120 can be selected according to actual conditions; for example, both can be made of 750L hot-formed steel sheet.

[0042] The first through-hole crossbeam assembly 130, the second through-hole crossbeam assembly 140, the cast balance shaft crossbeam 150, and the tail beam 160 are all transverse connecting components. They can all be sequentially fixed between the left longitudinal beam 110 and the right longitudinal beam 120 along a preset longitudinal extension direction (such as the longitudinal extension direction from the front to the rear of the vehicle) to enhance the strength and stability of the frame assembly 100.

[0043] Both the left longitudinal beam 110 and the right longitudinal beam 120 may include: a first constant cross-section segment 111, a variable cross-section segment 112, and a second constant cross-section segment 113 arranged sequentially in a predetermined longitudinal extension direction. Therefore, the left longitudinal beam 110 and the right longitudinal beam 120 are respectively referred to as the variable cross-section left longitudinal beam and the variable cross-section right longitudinal beam. The first constant cross-section segment 111 and the second constant cross-section segment 113 maintain constant cross-sectional shape and size to provide stable structural support; the variable cross-section segment 112 is where the cross-sectional shape or size of the longitudinal beam changes to adapt to varying stress requirements at different locations of the frame assembly 100.

[0044] The first through-beam assembly 130 is fixedly disposed between the first uniform cross-section section 111 of the left longitudinal beam 110 and the right longitudinal beam 120 to provide uniform lateral support at the front end of the frame and enhance the rigidity of the frame assembly 100 at the front end of the frame. The second through-beam assembly 140 is fixedly disposed between the variable cross-section section 112 of the left longitudinal beam 110 and the right longitudinal beam 120. Since the variable cross-section section 112 has changes in structural shape or size, the second through-beam assembly 140 can ensure the frame assembly 100 in this transition area. The strength and stability of the frame assembly 100 are enhanced by the casting balance shaft crossbeam 150 and the tail beam 160, which are sequentially fixed between the second equal section sections 113 of the left longitudinal beam 110 and the right longitudinal beam 120. The casting balance shaft crossbeam 150 is typically used to install key components such as the balance shaft of electric vehicles, while the tail beam 160 is used to enclose the rear end of the frame assembly 100. They provide necessary support at the rear end of the frame assembly 100, enhance the deformation resistance of the rear end of the frame assembly 100, and improve the overall strength and structural integrity of the frame assembly 100.

[0045] The pre-defined layout area between the first through-hole crossbeam assembly 130 and the second through-hole crossbeam assembly 140 is used to fix the battery system. Specifically, since the pre-defined layout area is defined by the first through-hole crossbeam assembly 130 and the second through-hole crossbeam assembly 140, and the first through-hole crossbeam assembly 130 is located between the first equal-section section 111 of the left longitudinal beam 110 and the right longitudinal beam 120, while the second through-hole crossbeam assembly 140 is located at the starting point of the variable-section section 112, the second through-hole crossbeam assembly 140 and the first through-hole crossbeam assembly 130 form a stable frame structure. This frame structure allows the pre-defined layout area to not only provide suitable installation space for the battery system but also improves the convenience of battery system hoisting operations. Compared to traditional frame assemblies, the single-sided clearance between the battery system and the longitudinal beams of the frame assembly 100 in this application is expanded, allowing technicians to easily perform hoisting operations and effectively avoiding the collision risk caused by confined spaces. Meanwhile, the stable frame structure protects the battery system. In the event of a collision or external impact on the electric vehicle, both the first through-hole crossbeam assembly 130 and the second through-hole crossbeam assembly 140 can withstand part of the impact force, reducing the risk of direct damage to the battery system. The preset layout area can be selected according to actual conditions.

[0046] The first through-hole crossbeam assembly 130 and the second through-hole crossbeam assembly 140 both feature through-hole designs, providing ample space for high-voltage lines, low-voltage lines, brake lines, water pipes, and other pipelines. This allows the pipelines to be arranged in an orderly manner without being compressed or bent, solving the problem of limited pipeline layout in traditional vehicle frames and reducing the risk of pipeline wear and failure.

[0047] The frame assembly provided in this application can be composed of a left longitudinal beam, a right longitudinal beam, a first through-hole crossbeam assembly, a second through-hole crossbeam assembly, a cast balance shaft crossbeam, and a tail beam. The left and right longitudinal beams are arranged opposite each other along a predetermined longitudinal extension direction. The first through-hole crossbeam assembly, the second through-hole crossbeam assembly, the cast balance shaft crossbeam, and the tail beam are sequentially fixed between the left and right longitudinal beams along the predetermined longitudinal extension direction, thereby forming a complete frame assembly. The left and right longitudinal beams are both designed as segmented structures consisting of a first equal cross-section segment, a variable cross-section segment, and a second equal cross-section segment arranged sequentially along the predetermined longitudinal extension direction. The first through-hole crossbeam assembly is fixed between the first equal cross-section segments of the left and right longitudinal beams, the second through-hole crossbeam assembly is fixed between the variable cross-section segments of the left and right longitudinal beams, and the cast balance shaft crossbeam and the tail beam are sequentially fixed between the second equal cross-section segments of the left and right longitudinal beams. The predetermined layout area between the first and second through-hole crossbeam assemblies is used to fix the battery system. Therefore, in the battery system of this application, since the first through-hole crossbeam assembly is located between the first equal-section sections of the left and right longitudinal beams, and the second through-hole crossbeam assembly is located at the starting point of the variable-section section, the second through-hole crossbeam assembly and the first through-hole crossbeam assembly form a stable frame structure. This frame structure allows the pre-laid layout area to not only provide suitable installation space for the battery system, but also improves the convenience of battery system hoisting operations. Secondly, since both the first and second through-hole crossbeam assemblies are provided with through holes, they provide ample passage space for high-voltage lines, low-voltage lines, brake lines, water pipes, and other pipelines. Even though the battery system occupies the pre-designed layout area in the center of the chassis, the pipelines can still freely pass through the through holes of the first and second through-hole beam assemblies, completely eliminating the problem of pipeline layout difficulties caused by insufficient clearance in traditional structures. This allows for a more reasonable pipeline arrangement, avoiding mutual friction and loss, improving the reliability of the entire vehicle's pipeline system, and greatly facilitating subsequent maintenance and repair. Furthermore, by setting the first and second through-hole beam assemblies between the variable cross-section section and the first constant cross-section section, and by directly connecting the upper and lower flanges of the left and right longitudinal beams without relying on the lower space of the chassis, this application allows the battery system to completely occupy the central area while the first and second through-hole beam assemblies can still evenly distribute the weight of the battery system and the impact force of the road surface to the entire length of the left and right longitudinal beams. This design breaks the limitation of ground clearance on the strength of the vehicle frame assembly, improves the torsional and bending resistance of the pre-laid layout area for battery system installation, effectively avoids the risk of deformation or breakage of the left and right longitudinal beams caused by local stress concentration in traditional vehicle frame assemblies, and improves the safety of electric vehicles in stable operation under complex working conditions.Furthermore, by connecting the left and right longitudinal beams at different longitudinal positions using multiple crossbeams (such as the first through-hole crossbeam assembly, the second through-hole crossbeam assembly, the cast balance shaft crossbeam, and the tail beam), the overall structural strength of the frame assembly is significantly improved. The crossbeams effectively distribute various loads during electric vehicle operation, such as impact forces from the road surface and static loads generated by the vehicle's own weight, thus preventing deformation or breakage of the left and / or right longitudinal beams. The design of constant and variable cross-section sections in the left and right longitudinal beams allows the frame assembly to be optimized according to actual stress conditions. The constant cross-section section provides a stable support foundation, while the variable cross-section section can flexibly adapt to the special stress requirements of different parts, thereby ensuring the stability of the frame assembly along its entire length.

[0048] Figure 2 is a schematic diagram of a frame assembly provided in an embodiment of this application. As shown in Figure 2, the left longitudinal beam 110 and the right longitudinal beam 120 have a first width (e.g., 970 mm) between them in the first equal cross-section section 111. That is, in the first equal cross-section section 111, the left longitudinal beam 110 and the right longitudinal beam 120 are parallel, and the distance between them remains constant, which is the first width (e.g., 970 mm). The left longitudinal beam 110 and the right longitudinal beam 120 have a second width (e.g., 850 mm) between them in the second equal cross-section section 113. That is, in the second equal cross-section section 113, the left longitudinal beam 110 and the right longitudinal beam 120 are parallel, and the distance between them remains constant, which is the second width (e.g., 850 mm), and the second width is less than the first width. The widths of the first and second widths can be selected according to actual conditions. For example, the first width can be selected as 970 mm, and the second width can be selected as 850 mm.

[0049] Because the variable cross-section section 112 of this application is moved to the rear end of the battery system, the first constant cross-section section 111 is widened. This allows the width of the left longitudinal beam 110 and the right longitudinal beam 120 between the variable cross-section section 112 to smoothly transition from a first width (e.g., 970mm) to a second width (e.g., 850mm) along a preset longitudinal extension direction. This not only provides sufficient space for lifting and maintenance of the battery system, improving the assembly efficiency and maintenance convenience of the battery system, but also allows the weight of the battery system and road impact loads to be evenly transmitted to the entire longitudinal beam section. Combined with the reinforcement effect of the second through-hole crossbeam assembly 140 at the starting point of the variable cross-section section 112, this further strengthens the rigidity of the frame in the transition area, effectively preventing the left and right longitudinal beams from cracking due to excessive local stress, and improving the reliability and durability of the overall vehicle structure. The first width (e.g., 970mm) and the second width (e.g., 850mm) are shown in red in Figure 2.

[0050] In this application, the pre-designed layout area of ​​the battery system on the frame assembly is located between the first through-beam assembly and the second through-beam assembly. The first through-beam assembly is positioned between the first constant cross-section sections, and the second through-beam assembly is positioned at the starting point of the variable cross-section section. Therefore, the pre-designed layout area has a first width (e.g., 970mm), making the width of the pre-designed layout area of ​​the battery system in the frame assembly larger. Thus, the left and right longitudinal beams on the frame assembly in this application can also be referred to as a widening structure from the first width to the second width. This, in turn, allows the widening design of the first constant cross-section section and the first and second through-beam assemblies to provide ample layout space for various pipelines.

[0051] For example, Figure 3 is a schematic diagram of a frame assembly provided in an embodiment of this application. As shown in Figure 3, since the battery system is located between the first through-hole crossbeam assembly 130 and the second through-hole crossbeam assembly 140, as can be seen from Figure 3(1), the layout area of ​​the battery system on the existing frame assembly is located in the rear end area of ​​the variable cross-section section, resulting in narrow space on both sides of the existing battery system layout area, with a single-sided spacing of only 22mm, making the installation and maintenance of the battery system extremely difficult. In contrast, the layout area of ​​the battery system on the frame assembly in this application is located in the front end area of ​​the variable cross-section section 112. That is, in this application, the variable cross-section section 112 on the frame assembly is moved to the rear of the battery system layout area (as shown in Figure 3(2)). Combined with the widening design of the first width (e.g., 970mm) between the left longitudinal beam 110 and the right longitudinal beam 120 in the first equal cross-section section 111 (traditionally 850mm), the spacing between the battery system and the frame assembly 100 is extended to 82mm. This not only improves the space of the battery system layout area but also ensures that the battery system has sufficient space for hoisting and maintenance, thereby improving the assembly efficiency and maintenance convenience of the battery system. For details, please refer to the red markings in Figure 3.

[0052] The frame assembly provided in this application has a first width between the left and right longitudinal beams in a first constant cross-section section that is greater than a second width between the left and right longitudinal beams in a second constant cross-section section. The width of the left and right longitudinal beams between the variable cross-section sections varies from the first width to the second width along a predetermined longitudinal extension direction. Therefore, the larger first width of the first constant cross-section section provides more spacious installation space for the battery system, ensuring sufficient lifting and maintenance space, improving the work efficiency of technicians, and reducing the possibility of operational errors. Secondly, the larger first width in the first constant cross-section section increases the lateral support span of the frame assembly, allowing the frame assembly to better distribute the weight load of the battery system and ensuring the strength of the frame assembly at the battery system mounting location.

[0053] Optionally, continuing to refer to Figure 1, the frame assembly 100 may also include: an upward-tilting crossbeam assembly 170.

[0054] The upward-turning crossbeam assembly 170 is fixedly disposed between the first equal-section sections 111 of the left longitudinal beam 110 and the right longitudinal beam 120, and is located between the first through-hole crossbeam assembly 130 and the second through-hole crossbeam 140 in a predetermined longitudinal extension direction. Since the predetermined layout area between the first through-hole crossbeam assembly 130 and the second through-hole crossbeam 140 is used to fix the battery system, the upward-turning crossbeam assembly 170 is located in the middle of the battery system installation, thereby strengthening the frame rigidity of the battery system installation area. Furthermore, because the upward-turning crossbeam assembly 170 is an upward-turning crossbeam, it provides additional longitudinal support without occupying the installation height space of the battery system.

[0055] The vehicle frame assembly provided in this application may further consist of an upward-folding crossbeam assembly. This upward-folding crossbeam assembly is fixedly disposed between the first equal-section sections of the left and right longitudinal beams, and is positioned between the first through-hole crossbeam assembly and the second through-hole crossbeam in a predetermined longitudinal extension direction. Therefore, the upward-folding crossbeam assembly of this application, working in conjunction with the first and second through-hole crossbeams, can more evenly distribute the weight load of the battery system onto the left and right longitudinal beams, preventing deformation of the battery system mounting area due to excessive localized stress. This enhances the torsional stiffness of the vehicle frame assembly, reduces torsional deformation in the battery mounting area, and protects the structural integrity of the battery system.

[0056] Figure 4 is a structural schematic diagram of an upward-turning crossbeam assembly provided in an embodiment of this application. As shown in Figure 4, the upward-turning crossbeam assembly 170 may include: two connecting supports 171 (172) and an upward-turning crossbeam 173.

[0057] As shown in Figure 1, the two connecting supports 171 (172) are fixedly connected to the left longitudinal beam 110 and the right longitudinal beam 120, respectively. The connecting support 171 is fixedly connected to the right longitudinal beam 120 by bolts, and the connecting support 172 is fixedly connected to the left longitudinal beam 110 by bolts. As shown in Figure 4, the two ends of the upward-turning crossbeam 173 are fixedly connected to the two connecting supports 171 (172) by bolts, forming a complete bridging structure that spans between the left and right longitudinal beams to ensure the strength of the frame assembly.

[0058] The upward-turning crossbeam 173 features a channel-shaped structure, using 750L hot-formed steel plate as the material to ensure high strength and stability. It is formed through a bending process, guaranteeing structural precision and consistency. Furthermore, to achieve a reliable connection, the upward-turning crossbeam 173 of this application employs a unique welding lap joint method, the details of which are shown in Figure 5(A). Figure 5 is a structural schematic diagram of a welding lap joint method for an upward-turning crossbeam provided in an embodiment of this application.

[0059] The frame assembly provided in this application comprises an upward-tilting crossbeam assembly consisting of two connecting supports and an upward-tilting crossbeam. The two connecting supports are fixedly connected to the left and right longitudinal beams, respectively, and both ends of the upward-tilting crossbeam are fixedly connected to the two connecting supports. Therefore, both the connecting supports and the upward-tilting crossbeam of this application adopt a split design, assembled by bolt connection, which reduces the manufacturing and assembly difficulty of the upward-tilting crossbeam assembly, facilitates later maintenance or replacement, and improves the overall vehicle assembly efficiency and ease of later maintenance.

[0060] Figure 6 is a structural schematic diagram of a first through-hole beam assembly provided in an embodiment of this application. As shown in Figure 6, the first through-hole beam assembly 130 may include: two first upper connecting plates 131 (132), two first lower connecting plates 133 (134), and a first through-hole beam 135.

[0061] The first through-hole beam 135 has through holes on its side to meet the layout requirements of internal pipelines (such as high-voltage lines, brake lines, etc.) of the electric vehicle, allowing the pipelines to pass through the first through-hole beam 135 and making reasonable use of the internal space of the frame; the two first upper connecting plates 131 (132) are respectively fixed to the two ends of the top surface of the first through-hole beam 135 by bolts, and the two first lower connecting plates 133 (134) are respectively fixed to the two ends of the bottom surface of the first through-hole beam 135 by bolts, so as to form a stable support for the first through-hole beam 135. Support structure; the two first upper connecting plates 131 (132) are also fixed to the top of the first equal section section 111 of the left longitudinal beam 110 and the right longitudinal beam 120 respectively by bolts, and the two first lower connecting plates 133 (134) are also fixed to the bottom of the first equal section section 111 of the left longitudinal beam 110 and the right longitudinal beam 120 respectively by bolts, so as to realize the connection between the first through hole crossbeam assembly 130 and the left and right longitudinal beams, and then firmly install the first through hole crossbeam assembly 130 on the frame, thereby ensuring the strength of the frame assembly.

[0062] It should be noted that the lengths of the two first lower connecting plates 133 (134) fixed to the bottom surface of the first through-hole beam 135 are greater than the lengths of the two first upper connecting plates 131 (132) fixed to the top surface of the first through-hole beam 135.

[0063] The frame assembly provided in this application comprises a first through-hole crossbeam assembly consisting of two first upper connecting plates, two first lower connecting plates, and a first through-hole crossbeam. The first through-hole crossbeam has through holes on its side. The two first upper connecting plates are respectively fixed to the two ends of the top surface of the first through-hole crossbeam, and the two first lower connecting plates are respectively fixed to the two ends of the bottom surface of the first through-hole crossbeam. The two first upper connecting plates are also respectively fixed to the top of the first equal cross-section sections of the left and right longitudinal beams, and the two first lower connecting plates are also respectively fixed to the bottom of the first equal cross-section sections of the left and right longitudinal beams. This is to evenly distribute the load borne by the first through-hole crossbeam assembly (such as the weight of the battery system, the impact force during vehicle operation, etc.) to the left and right longitudinal beams, avoid local stress concentration in the left and right longitudinal beams, enhance the load-bearing capacity of the frame, and enable the frame assembly to remain stable when subjected to external forces, reduce deformation, and improve the driving stability and handling of the electric vehicle.

[0064] Figure 7 is a schematic diagram of the side end structure of a first through-hole beam according to an embodiment of this application. As shown in Figure 7, the side end of the first through-hole beam 135 has a flared cut. In contrast, the side end of the existing first through-hole beam has a "C" shaped cut. Compared with the existing "C" shaped cut, the flared cut has a wider internal space, which can accommodate thicker or more numerous pipelines. Moreover, this flared cut is usually symmetrically distributed on both sides of the first through-hole beam 135, providing a larger cutting space for pipelines (such as high-voltage lines, low-voltage lines, brake lines, water pipes, etc.) passing through the first through-hole beam 135, effectively solving the problem of limited pipeline layout.

[0065] Furthermore, as shown in Figures 6 and 7 above, the flared cut of the first through-hole beam 135 is located at the side end of the first through-hole beam 135. The first through-hole beam 135 is fixed to the first equal section section 111 of the left longitudinal beam and the right longitudinal beam by bolts with the two first upper connecting plates 131 (132) and the two first lower connecting plates 133 (134), ensuring the stability of the first through-hole beam assembly 130 when bearing load; while the flared cut creates passage space for various pipelines without weakening the structural strength of the first through-hole beam assembly 130, so as to ensure that pipelines (such as high-voltage lines, low-voltage lines, brake lines, water pipes, etc.) can pass smoothly.

[0066] It should be noted that, since the end of the side of the first through-hole beam 135 in the first through-hole beam assembly 130 has a flared cut, the first through-hole beam assembly 130 can be called a "flared" type through-hole beam assembly.

[0067] The frame assembly provided in this application has a flared cut at the end of the side of the first through-hole crossbeam. Therefore, the first through-hole crossbeam assembly provided in this application can provide a larger cut space while meeting the frame strength requirements, ensuring sufficient space for the passage of high-voltage lines, low-voltage lines, brake lines, water pipes, etc.

[0068] Optionally, the second through-hole beam assembly 140 may include: two second upper connecting plates, two second lower connecting plates, and a second through-hole beam.

[0069] The second through-hole beam has through-holes on its side to accommodate the internal wiring (such as high-voltage lines and brake lines) of the electric vehicle, allowing the wiring to pass through the second through-hole beam and making reasonable use of the internal space of the frame. Two second upper connecting plates are fixed to the two ends of the top surface of the second through-hole beam, and two second lower connecting plates are fixed to the two ends of the bottom surface of the first through-hole beam, forming a stable support structure for the second through-hole beam. The two second upper connecting plates are also fixed to the top of the variable cross-section section 112 of the left longitudinal beam 110 and the right longitudinal beam 120, and the two second lower connecting plates are also fixed to the bottom of the variable cross-section section 112 of the left longitudinal beam 110 and the right longitudinal beam 120, so as to realize the connection between the second through-hole beam assembly 140 and the left and right longitudinal beams, thereby firmly installing the second through-hole beam assembly 140 on the frame and ensuring the strength of the frame assembly.

[0070] It should be noted that the second through-hole beam assembly 140 has an angled structural design, and its other structural functions are similar to those of the first through-hole beam assembly 130, so they will not be described in detail here.

[0071] For example, Figure 8 is a side structural schematic diagram of a second through-hole beam assembly and a first through-hole beam assembly provided in an embodiment of this application. As shown in Figure 8, since the first through-hole beam assembly 130 is disposed between the first equal cross-section segment 111 of the left longitudinal beam 110 and the right longitudinal beam 120, and the second through-hole beam assembly 140 is disposed at the starting position of the variable cross-section segment 112, the second through-hole beam assembly 140 is a beam with a preset tilt angle. The preset tilt angle can be selected according to the actual situation. For example, the preset tilt angle can be less than or equal to 5°.

[0072] The frame assembly provided in this application comprises a second through-hole crossbeam assembly consisting of two second upper connecting plates, two second lower connecting plates, and a second through-hole crossbeam. The second through-hole crossbeam has through holes on its side. The two second upper connecting plates are respectively fixed to the two ends of the top surface of the second through-hole crossbeam, and the two second lower connecting plates are respectively fixed to the two ends of the bottom surface of the first through-hole crossbeam. The two second upper connecting plates are also respectively fixed to the top of the variable cross-section sections of the left and right longitudinal beams, and the two second lower connecting plates are also respectively fixed to the bottom of the variable cross-section sections of the left and right longitudinal beams. This is to evenly distribute the load borne by the second through-hole crossbeam assembly (such as the weight of the battery system, the impact force during vehicle operation, etc.) to the left and right longitudinal beams, avoid local stress concentration in the left and right longitudinal beams, enhance the load-bearing capacity of the frame, and enable the frame assembly to remain stable when subjected to external forces, reduce deformation, and improve the driving stability and handling of the electric vehicle.

[0073] Optionally, the end of the second through-hole beam has a flared notch.

[0074] In one possible implementation, continuing to refer to Figure 8, the second through-beam assembly 140 is designed with a preset tilt angle, causing the end of the second through-beam to form a certain tilt angle with the longitudinal plane of the frame. This structural design is mainly to accommodate the spatial changes of the variable cross-section section 112 of the frame, while optimizing the passage path of pipelines in the tilted area. In contrast, the first through-beam 135 is arranged on the first constant cross-section section 111 of the frame, and its side end adopts a standard flared cut to meet the pipeline layout requirements. Because the preset tilt angle of the second through-beam compresses the lateral expansion space of the cut, the flared cut at the side end of the first through-beam 135 is larger in size than the flared cut at the end of the second through-beam, thus providing more ample passage space for pipelines.

[0075] It should be noted that, since the end of the side of the second through-hole beam in the second through-hole beam assembly 140 has a trumpet-shaped cut with a preset tilt angle, the second through-hole beam assembly 140 can be called an angled "trumpet" type through-hole beam assembly.

[0076] The frame assembly provided in this application has a flared cut at the end of the second through-hole crossbeam. Therefore, the second through-hole crossbeam assembly of this application can provide a larger cut space while meeting the frame strength requirements, ensuring sufficient space for high-voltage wires, low-voltage wires, brake lines, water pipes, etc., to pass through.

[0077] Figure 9 is a schematic diagram of a vehicle chassis structure provided in an embodiment of this application. As shown in Figure 9, the vehicle chassis structure 200 may include at least: a frame assembly 100, and a battery system 210 fixedly disposed in a predetermined layout area between the first through-hole crossbeam assembly and the second through-hole crossbeam assembly on the frame assembly 100.

[0078] Referring to Figures 1 and 9, the frame assembly 100, as the core load-bearing component of the chassis, provides the basic framework for the electric vehicle. It includes components such as the left longitudinal beam, right longitudinal beam, upward-tilting crossbeam assembly, first through-hole crossbeam assembly, second through-hole crossbeam assembly, upward-tilting crossbeam assembly, cast balance shaft crossbeam, and rear beam. The battery system 210 is fixedly installed in a pre-defined layout area between the first and second through-hole crossbeam assemblies within the frame assembly 100. This pre-defined layout area is designed to accommodate the size and installation requirements of the battery system 210.

[0079] The vehicle chassis structure provided in this application can be composed of a frame assembly and a battery system fixedly mounted on the frame assembly in a predetermined layout area between the first and second through-hole crossbeam assemblies. The predetermined layout area is defined by the first and second through-hole crossbeam assemblies, ensuring its dimensions match the battery system and guaranteeing its installation, avoiding installation difficulties or other interference problems due to insufficient space. Furthermore, the frame assembly 100 evenly distributes the weight of the battery system, preventing localized stress concentration and improving the frame assembly's load-bearing capacity for the battery system.

[0080] Figure 10 is a structural schematic diagram of an electric vehicle provided in an embodiment of this application. As shown in Figure 10, the electric vehicle 300 may include at least: a vehicle chassis structure 200.

[0081] Among them, the electric vehicle 300 may be equipped with a vehicle chassis structure 200, which provides a stable load-bearing and support platform for various components such as the body, battery system, motor, and electric drive axle, ensuring that the electric vehicle 300 maintains a stable posture during driving and avoiding shaking or damage caused by unstable component installation.

[0082] The electric vehicle provided in this application may include a vehicle chassis structure. Therefore, compared with vehicles in the prior art, the electric vehicle provided in this application can maintain good handling and stability during driving, reduce tilting, bumping, and veering, and improve driving safety.

[0083] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A vehicle frame assembly, characterized in that, The frame assembly includes: a left longitudinal beam, a right longitudinal beam, a first through-hole crossbeam assembly, a second through-hole crossbeam assembly, a cast balance shaft crossbeam, and a tail beam; the left and right longitudinal beams are arranged opposite each other along a predetermined longitudinal extension direction, and the first through-hole crossbeam assembly, the second through-hole crossbeam assembly, the cast balance shaft crossbeam, and the tail beam are sequentially fixed between the left and right longitudinal beams along the predetermined longitudinal extension direction; wherein, both the left and right longitudinal beams include: a first equal cross-section segment, a variable cross-section segment, and a second equal cross-section segment arranged sequentially along the predetermined longitudinal extension direction, the first through-hole crossbeam assembly is fixed between the first equal cross-section segment of the left and right longitudinal beams, the second through-hole crossbeam assembly is fixed between the variable cross-section segment of the left and right longitudinal beams, and the cast balance shaft crossbeam and the tail beam are sequentially fixed between the second equal cross-section segments of the left and right longitudinal beams; a predetermined layout area between the first and second through-hole crossbeam assemblies is used to fix the battery system.

2. The frame assembly according to claim 1, characterized in that, The first width between the left longitudinal beam and the right longitudinal beam in the first equal cross-section section is greater than the second width between the left longitudinal beam and the right longitudinal beam in the second equal cross-section section. The width between the left longitudinal beam and the right longitudinal beam in the variable cross-section section is the width that varies from the first width to the second width along the preset longitudinal extension direction.

3. The frame assembly according to claim 1, characterized in that, The frame assembly further includes an upward-folding crossbeam assembly, which is fixedly disposed between the first equal cross-section sections of the left longitudinal beam and the right longitudinal beam, and is located between the first through-hole crossbeam assembly and the second through-hole crossbeam in the preset longitudinal extension direction.

4. The frame assembly according to claim 3, characterized in that, The upward-turning crossbeam assembly includes: two connecting supports and an upward-turning crossbeam. The two connecting supports are respectively fixedly connected to the left longitudinal beam and the right longitudinal beam, and the two ends of the upward-turning crossbeam are respectively fixedly connected to the two connecting supports.

5. The frame assembly according to claim 1, characterized in that, The first through-hole beam assembly includes: two first upper connecting plates, two first lower connecting plates, and a first through-hole beam, wherein the side of the first through-hole beam has a through hole; the two first upper connecting plates are respectively fixed to both ends of the top surface of the first through-hole beam, the two first lower connecting plates are respectively fixed to both ends of the bottom surface of the first through-hole beam, the two first upper connecting plates are also respectively fixed to the top of the first equal cross-section section of the left longitudinal beam and the right longitudinal beam, and the two first lower connecting plates are also respectively fixed to the bottom of the first equal cross-section section of the left longitudinal beam and the right longitudinal beam.

6. The frame assembly according to claim 5, characterized in that, The end of the side of the first through-hole beam has a flared cut.

7. The frame assembly according to claim 1, characterized in that, The second through-hole beam assembly includes: two second upper connecting plates, two second lower connecting plates, and a second through-hole beam. The second through-hole beam has through holes on its side. The two second upper connecting plates are respectively fixed to the two ends of the top surface of the second through-hole beam, and the two second lower connecting plates are respectively fixed to the two ends of the bottom surface of the first through-hole beam. The two second upper connecting plates are also respectively fixed to the top of the variable cross-section sections of the left longitudinal beam and the right longitudinal beam, and the two second lower connecting plates are also respectively fixed to the bottom of the variable cross-section sections of the left longitudinal beam and the right longitudinal beam.

8. The frame assembly according to claim 7, characterized in that, The end of the second through-hole beam has a flared cut.

9. A vehicle chassis structure, characterized in that, It includes at least: the vehicle frame assembly as described in any one of claims 1 to 8, and a battery system fixedly disposed in a predetermined layout area between the first through-hole crossbeam assembly and the second through-hole crossbeam assembly on the vehicle frame assembly.

10. An electric vehicle, characterized in that, At least including: The vehicle chassis structure as described in claim 9.

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