A range-extended side-mounted frame

Abstract

The utility model relates to the field of new energy technology, and discloses a range-extended side-mounted frame, which includes a bottom crossbeam and bottom side crossbeams enclosing a "mu" - shaped bottom frame. Column crossbeams are fixedly connected to the four corner positions of the bottom frame. Side crossbeams are fixedly connected to the sides between adjacent column crossbeams to form a side frame. Middle crossbeams are evenly arranged in the middle area between the column crossbeams and are fixedly connected to the column crossbeams on both sides. Middle support crossbeams are arranged between adjacent middle crossbeams. A top bracket is connected between the middle crossbeams at the top. In the utility model, the design of the "mu" - shaped bottom frame + multi-layer crossbeams + reinforcing ribs constructs a three-dimensional stable frame, effectively resisting vibration and load. The reinforcing ribs precisely disperse the stress at the top corners, greatly enhancing the torsional strength of the frame, making the structure of the frame more stable and extending the service life of the frame.

Description

Technical Field

[0001] The utility model relates to the technical field of new energy, in particular to an extended-range side-mounted frame. Background Art

[0002] With the gradual penetration of new energy into the heavy truck industry, which is gradually shifting from fuel to the new energy field, more and more vehicle manufacturers are researching new methods with longer endurance and faster energy replenishment. Due to the slow energy replenishment and insufficient endurance of the traditional pure-electric structure, it has gradually been replaced by battery swapping; the battery swapping mode also has poor results due to the large investment in operating battery swapping stations. In view of this, the extended-range structure of the hybrid mode gradually highlights its advantages. The extended-range vehicle uses "battery + range extender (fuel engine for power generation)" as the power source. In the pure-electric mode, it can meet daily driving. When driving long distances, the range extender starts to generate electricity. In theory, as long as there is fuel, it can continue to drive. When the battery of a pure-electric vehicle runs out of power, it cannot drive and needs to be towed or charged; even if the battery of an extended-range vehicle runs out of power, the range extender can continue to supply power to avoid the risk of breakdown.

[0003] With the rapid development of the new energy heavy truck industry, there are many technical defects in the traditional power structure and the existing battery frame:

[0004] 1. The torsional strength of the frame structure is insufficient. Simple welding or bolt connection is mostly used, and the vibration and impact during vehicle operation are likely to cause the frame to deform, affecting the service life of components;

[0005] 2. The installation of the skin is inefficient. The traditional tapping method causes great damage to the base material of the frame, the connection strength of the skin is low, the assembly process is complex, and the use of a metal skin results in a large weight and poor weather resistance. Content of the Utility Model

[0006] In order to make up for the above deficiencies, the utility model provides an extended-range side-mounted frame with high torsional strength and a stable structure, as well as an efficient skin installation method.

[0007] In order to achieve the above object, the utility model adopts the following technical scheme: An extended-range side-mounted frame includes a bottom frame formed by enclosing a "mu" shape with a bottom cross beam and bottom side cross beams. Column cross beams are fixedly connected to the four corner positions of the bottom frame. Side cross beams are fixedly connected to the sides between adjacent column cross beams to form a side frame. Middle cross beams are evenly arranged in the middle area between the column cross beams and are fixedly connected to the column cross beams on both sides. Middle support cross beams are arranged between adjacent middle cross beams. A top bracket is connected between the middle cross beams at the top. A bottom skin covers the bottom of the bottom frame, and a side skin covers the outside of the side frame.

[0008] As a further description of the above technical scheme:

[0009] Connecting crossbeams are installed between the middle crossbeams and between the bottom crossbeams on the same horizontal plane.

[0010] As a further description of the above technical solution:

[0011] The connecting crossbeam is arranged between two adjacent bottom side crossbeams, and the position of the connecting crossbeam on the middle crossbeam corresponds to that on the bottom frame.

[0012] As a further description of the above technical solution:

[0013] Both ends of the connecting crossbeam are detachably connected with connecting components, and the connecting components include U-shaped plates, sleeves and nuts.

[0014] As a further description of the above technical solution:

[0015] The U-shaped plate straddles between the middle crossbeam and the connecting crossbeam, the sleeve passes through the through holes corresponding to the U-shaped plate, the middle crossbeam and the connecting crossbeam, and the nut is threadedly connected with the sleeve to tightly connect the middle crossbeam and the connecting crossbeam.

[0016] As a further description of the above technical solution:

[0017] Reinforcing ribs are installed at the top corners of the frame structure, and the included angle between the reinforcing ribs and the crossbeam is 45° - 60°.

[0018] As a further description of the above technical solution:

[0019] Mounting components for connecting the frame crossbeams are symmetrically and fixedly connected to the outside of the middle crossbeam.

[0020] As a further description of the above technical solution:

[0021] At the top corners of the frame structure, sealing plates are arranged at the ends of the crossbeams.

[0022] As a further description of the above technical solution:

[0023] The skin is made of CFRT thermoplastic sheet.

[0024] The utility model has the following beneficial effects:

[0025] 1. In the utility model, firstly, the design of the "eye" - shaped bottom frame + multi - layer crossbeams (middle crossbeams, connecting crossbeams) + reinforcing ribs constructs a three - dimensional stable frame, effectively resisting vibration and load. The reinforcing ribs accurately disperse the stress at the top corners, greatly enhancing the torsional strength of the frame, making the structure of the frame more stable and extending the life of the frame; the connecting components achieve rigid connection between the crossbeams through the "clamping" of the U - shaped plate + sleeve passing through + nut tightening, and the anti - loosening ability is far better than that of traditional bolts.

[0026] 2. In this utility model, the skin is installed using a hot melt drill for tapping, eliminating the need for pre-drilling and directly machining the internal threads, reducing damage to the frame base material and improving connection strength and assembly efficiency; the skin is made of CFRT thermoplastic sheet, which is lighter than metal skin and has flame-retardant, weather-resistant and recyclable properties. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the structure of a range-extended side-mounted frame proposed in this utility model;

[0028] Figure 2 This utility model proposes a range-extended side-mounted frame. Figure 1 A magnified view of point A;

[0029] Figure 3 This is a front view of a range-extended side-mounted frame proposed in this utility model.

[0030] Legend:

[0031] 1. Installation components; 2. Bottom crossbeam; 3. Bottom side crossbeam; 4. Column crossbeam; 5. Side crossbeam; 6. Middle crossbeam; 7. Connecting crossbeam; 8. Middle support crossbeam; 9. Top bracket; 10. Reinforcing rib; 11. Side skin; 12. Bottom skin; 13. Sealing plate; 14. Nut; 15. Sleeve; 16. U-shaped plate. Detailed Implementation

[0032] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0033] Example 1, referring to Figure 1-2 An extended-range side-mounted frame includes a bottom frame formed by a bottom crossbeam 2 and bottom side crossbeams 3, which serves as the bottom support foundation. Vertical crossbeams 4 are fixedly connected to the four corners of the bottom frame, acting as vertical support columns connecting the bottom and top structures. Side crossbeams 5 are fixedly connected to the sides of adjacent vertical crossbeams 4, forming a side frame and providing lateral support. A central crossbeam 6 is evenly distributed in the middle area between the vertical crossbeams 4, fixedly connected to the two side vertical crossbeams 4 to strengthen lateral support. A central support crossbeam 8 is provided between adjacent central crossbeams 6 to improve the torsional resistance of the middle of the frame. A top bracket 9 is connected between the central crossbeams 6 at the top, forming a top support frame suitable for external device installation.

[0034] The bottom frame is covered with a bottom skin 12, which closes the bottom opening. The outer side of the side frame is covered with a side skin 11, which closes the side opening. The skin is made of CFRT thermoplastic sheet, which is lighter than metal skin and has flame-retardant, weather-resistant and recyclable properties. During installation, a hot melt drill is used to tap the holes. For the installation positions of the bottom skin 12 and the side skin 11, internal thread holes are machined using a hot melt drill (process parameters: temperature 800~1000℃, pressure 5~10MPa). After tapping, the residue in the holes is cleaned, and the thread accuracy is checked (compliant with GB / T196 standard). The skin is fixed to the bottom frame and the side frame with bolts. The bolt preload is ≥15N・m to ensure that the skin is not loose. The use of a hot melt drill to machine the internal thread holes eliminates the need for pre-drilling, reduces damage to the base material, and improves connection strength and assembly efficiency.

[0035] Example 2, refer to Figure 2 Connecting beams 7 are installed between the middle crossbeams 6 and between the bottom crossbeams 2 on the same horizontal plane for mounting the range extender battery pack. The connecting beams 7 and the middle crossbeams 6 are on the same horizontal plane, ensuring the flatness of the battery bottom, increasing the contact area to reduce pressure on the middle crossbeam 6, and enhancing lateral connection rigidity. The connecting beams 7 are positioned between two adjacent bottom side crossbeams 3, and the positions of the connecting beams 7 on the middle crossbeams 6 correspond to those on the bottom frame. The two ends of the connecting beams 7 can... The disassembly and connection are achieved through a connecting assembly, which includes a U-shaped plate 16, a sleeve 15, and a nut 14. The U-shaped plate 16 spans between the middle crossbeam 6 and the connecting crossbeam 7. The sleeve 15 passes through the corresponding through holes in the U-shaped plate 16, the middle crossbeam 6, and the connecting crossbeam 7. The nut 14 is threadedly connected to the sleeve 15 to securely connect the middle crossbeam 6 and the connecting crossbeam 7. The connecting assembly achieves a rigid connection between the crossbeams through the "clamping" of the U-shaped plate, the insertion of the sleeve, and the tightening of the nut. Its resistance to loosening is far superior to that of traditional bolts.

[0036] Example 3, referring to Figure 3 At the top corner of the frame structure, such as the angle between the side crossbeam 5 and the column crossbeam 4, a reinforcing rib 10 is installed. The angle between the reinforcing rib 10 and the crossbeam is 45°~60°, which disperses stress and enhances the resistance to deformation. The outer side of the middle crossbeam 6 is symmetrically fixed with a mounting component 1 for connecting the frame crossbeam. The mounting component 1 is fixed to the frame crossbeam with 16 M12 bolts. The modular side layout (such as independent battery packs on the left and right sides) allows the battery pack on one side to be disassembled independently. When a battery pack fails, it can be disassembled and repaired directly on the side of the frame, which can shorten the repair time by more than 50%. At the top corner of the frame structure, the end of the crossbeam is provided with a sealing plate 13 to close the end of the crossbeam at the top corner of the frame and prevent impurities from entering.

[0037] Assembly method: When assembling this frame, first perform the frame assembly: weld the bottom cross beam 2 and the bottom side cross beam 3 into a "mu" shaped base; weld the column cross beam 4 at the four corners and the side cross beam 5 on the side; install the middle cross beam 6 and the middle support cross beam 8, and add a bracket 9 on the top; then install the connecting cross beam 7: horizontally fix the connecting cross beam 7 and the middle cross beam 6 through the connecting components U-shaped plate 16, sleeve 15 and bolt 14; then perform the vehicle frame connection: fix the installation component 1 to the vehicle frame cross beam with 16 M12 bolts; subsequently perform the skin assembly: directly tap the surface of the cross beam by hot melt drilling and fasten the CFRT skin to the outside of the frame; finally weld the 45° - 60° reinforcing ribs 10 at the top corners and add a sealing plate 13 at the end of the cross beam, and the assembly of this side-mounted frame is completed.

[0038] Finally, it should be noted that the above are only the preferred embodiments of the present invention and are not used to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, for those skilled in the art, they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements for some of the technical features. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A range-extender side frame, comprising a bottom frame enclosed by a bottom cross beam (2) and bottom side cross beams (3) in the shape of an "eye", characterized in that: The bottom frame is fixedly connected to the four corners of the column beams (4), and the sides of the adjacent column beams (4) are fixedly connected to the side beams (5) to form the side frame. The middle area between the column beams (4) is evenly provided with the middle beams (6), which are fixedly connected to the column beams (4) on both sides. The middle support beams (8) are provided between the adjacent middle beams (6). The middle beams (6) at the top are connected to the top brackets (9). The bottom of the bottom frame is covered with a bottom skin (12), and the outside of the side frame is covered with a side skin (11). The skin is tapped with a hot melt drill during installation.

2. The range extending side frame of claim 1, wherein: Connecting beams (7) are installed between the middle beams (6) and between the bottom beams (2) on the same horizontal plane.

3. The range extending side frame of claim 2, wherein: The connecting beam (7) is set between two adjacent bottom side beams (3), and the position of the connecting beam (7) on the middle beam (6) corresponds to that on the bottom frame.

4. The range extending side frame of claim 3, wherein: The two ends of the connecting beam (7) are detachably connected to connecting components, which include a U-shaped plate (16), a sleeve (15) and a nut (14).

5. The range extending side frame of claim 4, wherein: The U-shaped plate (16) spans between the middle crossbeam (6) and the connecting crossbeam (7). The sleeve (15) passes through the corresponding through holes of the U-shaped plate (16), the middle crossbeam (6) and the connecting crossbeam (7). The nut (14) is threadedly connected to the sleeve (15) to securely connect the middle crossbeam (6) and the connecting crossbeam (7).

6. The range extending side frame of claim 1, wherein: The frame structure is equipped with a reinforcing rib (10) at the top corner, and the angle between the reinforcing rib (10) and the crossbeam is 45°~60°.

7. The range extending side frame of claim 1, wherein: The outer side of the central crossbeam (6) is symmetrically fixed with mounting components (1) for connecting the frame crossbeam.

8. The range extending side frame of claim 1, wherein: At the top corner of the frame structure, the ends of the crossbeams are provided with sealing plates (13).

9. A range-extended side-mounted frame according to claim 1, characterized in that: The skin is made of CFRT thermoplastic sheet.

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