Structural member for vehicle

Abstract

The utility model relates to a kind of structural members for vehicle, the structural member can be connected with vehicle in at least two mutually spaced apart connecting areas (21A,21B) to receive force, the connecting area is integrally formed with the grid cast structure (22) of the space formed in single piece, the grid cast structure includes multiple diagonal bracing rod type connecting elements (23~36) formed by solid material, corresponding one connecting element is fixedly connected with the rest of grid cast structure via at least two node areas (37~52) on the side of connecting area and does not overlap with another connecting element in stripping direction (Z) except in node area. The structural member can be manufactured cheaply and has small component weight.

Description

Technical Field

[0001] This utility model relates to a structural component for vehicles. Background Technology

[0002] A frame-shaped axle support, particularly for the rear axle of a motor vehicle, is known from DE102004012662B4. This axle support essentially comprises two crossbeams and two longitudinal beams. The crossbeams and longitudinal beams are constructed from substantially closed hollow profiles having a wall thickness on the order of 3 mm to 6 mm. The frame-shaped axle support is manufactured as a single piece of aluminum alloy using a cold-casting (Kokillenguss) method with a so-called lost-core construction.

[0003] Such conventional cast structures with tubular forms need to be manufactured with the smallest possible wall thickness to achieve low component weight. This is technically challenging and results in high manufacturing costs due to its complexity. Utility Model Content

[0004] The objective of this invention is to provide a structural component that can be manufactured inexpensively and has a small component weight.

[0005] The task is solved by means of a structural member for a vehicle according to the present invention, which can be connected to the vehicle in at least two spaced-apart connection areas to receive forces. The connection areas are integrally formed with a single-piece spatial grille casting structure, which includes a plurality of connecting elements in the form of diagonal struts made of solid material. Each connecting element is fixedly connected to the rest of the grille casting structure on the connection area side via at least two node areas and does not overlap with other connecting elements in the demolding direction except in the node areas.

[0006] Advantageous embodiments of this utility model are described in the specification.

[0007] One aspect of this utility model relates to a structural member for a vehicle, the structural member being connectable to the vehicle in at least two spaced-apart connection regions to receive forces. The connection regions form force-introducing or force-transmitting regions of the structural member, and are integrally formed with a monolithically constructed spatial grid casting structure comprising a plurality of diagonal strut-like connecting elements made of solid material. The connecting elements may be rib-shaped or strip-shaped, and may be configured as so-called wires or the like. Each connecting element is fixedly connected to the remainder of the grid casting structure via at least two node regions on the force-introducing side, and does not overlap with other connecting elements in the demolding direction except in the node regions; therefore, despite the spatial grid structure, the structural member can be demolded in one direction.

[0008] The structural components according to this invention can be manufactured inexpensively and have a small component weight. Furthermore, compared to structural components with a cast hollow structure, there is greater freedom in placing the necessary materials within the available space, and the proportion of lost core is reduced because the connecting elements are made of solid material.

[0009] The coreless, cast-in-place, spatial grid structure or bar structure of the present invention can be manufactured with significantly more variations in cross-section to meet practical needs and correspondingly with orientations that extend in the usable structural space and adapt to the loads acting on the structural member.

[0010] In structural members with hollow structures, the minimum cross-section of these hollow structures is determined by the minimum possible diameter of the sand core. Here, the minimum possible diameter of the sand core corresponds to a diameter above which the sand core will not break between core extraction and casting. Additionally, the minimum possible diameter is also related to a minimum spacing that needs to be maintained between the sand core and the mold to avoid inhomogeneities in the cast structural member. This results in such structural members having large cross-sections.

[0011] In contrast, coreless, ribbed or strip-shaped connecting elements, or connecting elements made of solid material without hollow structures, can form significantly smaller cross-sectional areas because the cross-section of these connecting elements is formed only by the corresponding outer walls in terms of height and width.

[0012] Therefore, the structural components according to this utility model can be constructed with good component strength-component weight-proportion, and the structural components have a spatial grid structure or bar structure that can be manufactured in casting technology and is essentially coreless.

[0013] Furthermore, the structural components according to this invention meet an important requirement: the structural components include a spatial grid structure or strip structure that can be manufactured using casting technology, and the grid structure can be demolded in one direction. This is because the connecting elements do not overlap with other connecting elements in the demolding direction, except in the node region.

[0014] Furthermore, the spatial grid structure, or strip structure, is configured such that it occupies as much usable structural space as possible not only in the direction perpendicular to the demolding direction but also in the demolding direction itself. It also allows for significant variations in the orientation of each connecting element and in the cross-section of the connecting elements both in the demolding direction and in the direction perpendicular to the demolding direction, or it can be configured to adapt to variations in the parting surface for corresponding orientations. Therefore, the structural member can achieve the required member strength while maintaining a low component weight.

[0015] Furthermore, since the connecting elements are made of solid material, the replenishment of structural component blanks during the cooling stage after casting can be of high quality. Because the cross-section of the casting channels (in which connecting elements, connection areas, and node areas are manufactured) is significantly larger than the cross-section of the downstream casting channels (in which hollow structures are manufactured), the tailing of casting material during the cooling stage is significantly simpler and can be achieved within the range required to avoid shrinkage cavities.

[0016] When the demolding ramp of the connecting element has a demolding angle relative to the demolding direction, the structural member is characterized by particularly good demoldability, above and / or below the parting surface or the casting parting area, the demolding angle being equal to or greater than the minimum demolding angle required for industrial demolding.

[0017] In one embodiment of the structural member that is easy to manufacture, the embodiment is further characterized by high strength, wherein the connecting elements are arranged to extend through or overlap each other at least partially in the node region and are fixedly connected to each other.

[0018] The structural member has high member strength when at least one connecting element extends from one connecting region to at least one other connecting region and intersects with at least one other connecting element between the connecting regions, the other connecting elements being connected in the same manner and method. It can be specified here that one of the connecting regions is a force-introducing region, for example, a guide rod for a wheel is connected to this force-introducing region. It is also possible that the other connecting region is a force-transmitting region, for example, a structural member preferably configured as an axle support is connected to the vehicle body via this force-transmitting region.

[0019] When the cross-section of at least one of the connecting elements varies at least locally, the design of the structural member's load-bearing capacity can be achieved while minimizing the member's weight.

[0020] The grille casting structure can enclose a receiving space in which an axle differential or motor can be installed and fixedly connected to the structural components.

[0021] The structural component can be configured as a rear axle support for a vehicle.

[0022] In addition, a method for manufacturing such structural components that can be easily implemented should be developed.

[0023] Another aspect of this invention relates to a method for manufacturing structural components described in more detail above, wherein the connecting regions and the grid casting structure are at least partially manufactured in an inexpensive manner and by means of a cold casting process that can be performed with substantially no loss of the core.

[0024] Because structural components are manufactured using cold casting technology, the connecting elements can be geometrically continuous in a simple manner. It is possible that the connecting elements can be geometrically continuous not only in a single plane in the longitudinal direction, but also in three-dimensional space.

[0025] The connecting elements and node areas of the structural components, after the cold casting process, already have a geometrically continuous orientation in their unprocessed state along the so-called stamped edges. The cross-section of the connecting element is mainly determined by the demolding ramp, particularly by its height and width, and the cross-section of the connecting element has a geometrically continuous orientation in the node area between the force introduction region and the force transmission region. Here, the connecting element can be configured with a varying cross-section in the longitudinal direction of the connecting element with minimal cost, according to the corresponding requirements to be met.

[0026] The orientation of the connecting elements can be determined in a simple manner based on the force vector—which extends directly between the connecting regions, i.e., between the force introduction region and the force transmission region, or in other words, directly connects these connecting regions—and based on the structural space provided in the vehicle for arranging the grille casting structure.

[0027] The points of application of the force vectors are located in the force introduction region and the force transmission region, respectively. The direction and length of the force vectors are generated by the load, which the structural member is subjected to during operation.

[0028] The free space between the connecting elements of the grid casting structure can be manufactured in a cost-effective manner and by means of stamping after a cold casting process, using small manufacturing techniques.

[0029] The node regions, or the casting parting regions of the intersecting connecting elements, extend at the same height in the demolding direction. Each casting parting region, or parting surface, converges at the same height, allowing for an ascent angle relative to the demolding direction of no more than one defined angle, so that it can be stamped in the demolding direction. Because a large change in the orientation of the connecting elements is also pursued in the demolding direction, the ascent of each parting surface can result in a larger node region, not only in the demolding direction but also in the orientation direction of the connecting elements. This is particularly applicable when more than two connecting elements intersect.

[0030] Furthermore, there is the possibility that, in areas of the grating casting structure, cores may be locally employed during the cold casting process to avoid unnecessary material buildup. This could be, for example, in node areas where more than two overlapping connecting elements in the demolding direction of the structural member intersect and these connecting elements have excessively long rises in the parting surface. Additionally, in areas of threaded domes—where the threaded domes extend in the demolding direction of the structural member and the distance between the interface of the threaded dome on the connecting element and the parting surface is greater than the length required for the threaded connection—there is the possibility that material buildup detrimental to casting process quality can be mitigated by employing localized cores, and weight can be reduced.

[0031] The orientation and cross-section of the connecting element between the guide rod connection and the support connection can be determined using an AI-based optimization method, taking into account the parting surface, demolding direction, and necessary demolding ramps, in order to accelerate development. Furthermore, it is advantageous to subsequently perform manual construction with minimal overhead by utilizing the determined orientation and cross-section of the connecting element for parameter optimization.

[0032] The basic principles of the construction and manufacturing methods of this utility model are based on a structure in which the connecting elements form so-called wires made of solid material, and the connecting elements pass through the usable space volume between the nodes of the force-introducing nodes with the curvature as continuously as possible. Here, high component stiffness is achieved through multiple intersections or node regions between the connecting elements, or wires, which extend in the X direction (longitudinal direction) and in the Y direction (lateral direction) of the structural member (the X and Y directions constitute the component plane or horizontal plane of the structural member), and in the Z direction (height direction) of the structural member, and ideally the connecting elements are arranged relative to each other in fewer than three overlapping layers.

[0033] Simultaneously, the structural member has a grid casting structure that can be demolded perpendicularly to the plane of the member. This grid casting structure forms a truss or spatial grid, which can be cast in a mold. This is because the connecting elements of the grid casting structure have the necessary relative spacing to each other in the X and Y directions. This allows for inexpensive manufacturing, either without a core, such as a sand core, or requiring significantly fewer cores compared to known structural members.

[0034] In other words, conventional or printed sand cores are needed to a much less extent compared to existing technologies, thus enabling more economical manufacturing.

[0035] Additionally, the method according to this invention allows for the adaptive orientation of the routing of each connecting element or wire between the connecting areas, as well as the adaptation of the volume or cross-section of each connecting element or wire between the connecting areas to meet load requirements. Therefore, the amount of material required to meet functional objectives can be allocated with significantly greater variation compared to known solutions. Consequently, the structural components according to this invention can be manufactured with a good ratio between component strength and component weight while maintaining low cost.

[0036] Other features of this utility model are derived from the accompanying drawings and the description thereof. The features and combinations thereof mentioned in the foregoing description, as well as those mentioned in the following description and / or shown separately in the drawings, can be applied not only in the correspondingly described combinations, but also in other combinations or individually. Attached Figure Description

[0037] The present invention will now be explained in more detail with the aid of preferred embodiments and with reference to the accompanying drawings. The drawings are as follows:

[0038] Figure 1 Showing a perspective view of the vehicle's rear axle support as known in the prior art; and

[0039] Figure 2 Showing a partial perspective view of the structural member of the present invention that forms the rear axle support of a vehicle. Detailed Implementation

[0040] Figure 1 The rear axle support 1, as known in the prior art, includes multiple spaced-apart connection regions 2A-2D, 3A-3D, and 4A-4D. Rear axle support members are provided in connection regions 2A-2D, via which the rear axle support 1 can be connected to a vehicle body (not described in further detail). In the other connection regions 3A-3D and 4A-4D, transverse and longitudinal guide rods can be fixed to the rear axle support 1.

[0041] The known rear axle support 1 forms a structural member with hollow structures 1A to 1D, which are manufactured by cold casting and define a structural space 5. For example, an axle differential or motor can also be disposed within the structural space 5 and connected to the rear axle support 1. Prior to the actual casting process, a sand core or similar material is placed in the casting mold or die to create the cavities of the hollow structures 1A to 1D. However, a significant drawback is that the sand core needs to be destroyed after casting in order to remove it from the interior of the hollow structures 1A to 1D.

[0042] exist Figure 2 The image shows a structural member 20 for a vehicle, manufactured by cold casting. This structural member serves as a rear axle support and is connected to the vehicle within spaced-apart connection areas 21A and 21B to receive forces. The connection areas 21A and 21B are integrally formed with a single-piece spatial grille casting structure 22 and designed to receive the support unit. The grille casting structure 22 includes multiple diagonal strut-type connecting elements 23-36, which are made of solid material. Furthermore, in... Figure 2 The envelope geometry of the hollow structures 60, 61 for spatial orientation, which are replaced by the grid casting structure 22 of the rear axle support, is described in the side regions S1 and SII of the structural member 20.

[0043] Connecting elements 23-36 are fixedly connected to the remainder of the grid casting structure 22 via at least two node regions 37-52, and do not overlap with other connecting elements in the demolding direction Z except in node regions 37-52. Furthermore, the connecting elements 23-36 have a geometrically continuous orientation in their longitudinal extension dimension. Additionally, the connecting elements 23-36, originating from the casting parting region 53, respectively form demolding ramps 54 and 55 in the demolding direction Z.

[0044] Depending on the loads acting on the connecting elements 23-36, these elements are at least partially passed through or overlapped in the node regions 37-52 and are fixedly connected to each other, so that the grille casting structure 22 can be constructed with the highest possible component stiffness while minimizing component weight. Connecting element 27 extends from connecting region 21A to another connecting region 21B, thus allowing lateral forces acting on the rear axle support 20 to be supported in a structurally simple manner within the vehicle body area. Furthermore, the cross-sections of connecting elements 23-36 vary with the load in their longitudinal directions, so that the grille casting structure 22 can be constructed with the necessary component strength using the least amount of material.

[0045] Similar to the rear axle support 1, the grille casting structure 22 surrounds the housing 5, in which, for example, an axle differential or motor can be housed and fixedly connected to the structural member 20.

[0046] The free space 56 between the connecting elements 23 to 36 of the grid casting structure 22 follows the casting parting area 53 in the minimum cross-section of the connecting elements, and the casting tenon is removed by stamping after the casting process.

[0047] The orientation of the connecting elements 23-36 is determined based on the main force line connecting the connecting regions 21A and 21B and the structural space provided in the vehicle for arranging the grille casting structure 22. As many nodes as possible with the secondary force line should be generated here, with as little overlap as possible between more than two connecting elements. Furthermore, the available cross-section of the structural space with planar rotational inertia should be fully utilized to achieve the required stiffness.

[0048] In other areas of the grid casting structure 22, such as in node regions 46, 47, 31, 50, or 52 (where more than two overlapping connecting elements 27, 35, and 24 intersect in the height direction Z of the structural member and do not have a stepped rise parallel to the horizontal plane XY of the structural member 20), cores, such as sand cores or the like, can be used during the casting process. This can also be specified in the region of the threaded dome 57, which extends in the height direction Z of the structural member 20, and the distance between the interface of the threaded dome and the connecting element 32 and the casting parting region 53 is greater than the length required for the threaded connection. Therefore, excessive material accumulation that may impair the quality of the cold-casting process can be avoided, as well as the potential weight disadvantages of this principle.

[0049] The orientation and cross-section of the connecting elements 23-36 can be rapidly determined using an AI-based optimization method, taking into account the required parting surface, demolding direction, and demolding ramp, between the guide rod connection and support member connection of the rear axle support 20 (not described in more detail). Manual construction with optimized parameters is performed using the orientation and cross-section of the connecting elements 23-36 to design the rear axle support 20 to be as load-bearing and adaptable as possible while maintaining a low component weight.

[0050] List of reference numerals

[0051] 1. Rear axle support

[0052] Hollow structure 1A-1D

[0053] The connection area of ​​rear axle support 1 (2A-2D)

[0054] The connection area of ​​rear axle support 1 (3A-3D)

[0055] The connection area of ​​rear axle support 1 (4A-4D)

[0056] 5. Structural space of rear axle support 1

[0057] 20 Structural components, rear axle support,

[0058] The connection area of ​​rear axle supports 20 (21A, 21B)

[0059] 23-36 Connecting elements,

[0060] Nodes 37-52

[0061] 53. Casting parting area.

[0062] 54, 55 Demolding slope,

[0063] 56. Free space

[0064] 60, 61 Hollow structure,

[0065] Areas of structural member 20 in SI and SII

[0066] The longitudinal direction of X-structure member 20

[0067] The horizontal plane of structural member 20 in the XY region.

[0068] The transverse direction of Y-structure member 20

[0069] Z structural component 20: height direction and demolding direction.

Claims

1. A structural member for a vehicle, the structural member being connectable to the vehicle in at least two spaced-apart connection areas (21A, 21B) to receive forces, characterized in that, The connecting areas (21A, 21B) are integrally formed with a single-piece grating casting structure (22) comprising a plurality of connecting elements (23-36) in the form of diagonal struts made of solid material. Each connecting element is fixedly connected to the rest of the grating casting structure (22) via at least two node areas (37-52) on the connecting area (21A, 21B) side and does not overlap with other connecting elements in the demolding direction (Z) except in the node areas (37-52).

2. The structural component for a vehicle according to claim 1, characterized in that, The demolding ramps (54, 55) of the connecting elements (23-36) have a demolding angle relative to the demolding direction (Z), above and / or below the casting parting area (53), and the demolding angle is equal to or greater than the minimum demolding angle required for industrial demolding.

3. The structural component for a vehicle according to claim 1 or 2, characterized in that, The connecting elements (23-36) are arranged to extend through or overlap each other at least partially in the node regions (37-53) and are fixedly connected to each other.

4. The structural component for a vehicle according to claim 1 or 2, characterized in that, At least one connecting element extends from one connecting area to at least one other connecting area.

5. The structural component for a vehicle according to claim 1 or 2, characterized in that, The cross-section of at least one of the connecting elements (23-36) varies at least locally.

6. The structural component for a vehicle according to claim 1 or 2, characterized in that, The grille casting structure (22) surrounds the receiving space (5), in which the axle differential or motor can be installed and fixedly connected to the structural member (20).

7. The structural component for a vehicle according to claim 1 or 2, characterized in that, The structural component (20) constitutes the rear axle support of the vehicle.

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