Frame type vehicle frame grounding structure and vehicle

Abstract

The utility model belongs to the vehicle engineering and electrical connection technical field provides a frame formula frame ground connection structure and vehicle, this connection structure includes at least one group of mutual connection metal member, and the connecting place of metal member is connected through at least one group of double bolt redundancy unit, and the double bolt redundancy unit for realizing mechanical fastening and electrical connection includes two parallelly arranged iron bolt, and the iron bolt surface is provided with zinc nickel alloy plating. The utility model completes the ground connection of the loose piece electrophoresis frame under the premise of not adding any part, has low cost, easy operation and process compatible advantage, and the redundancy design guarantees the stability of electrical system, and the structure can be popularized to other frame formula structure vehicle, adapts to the demand of multiple scenes.

Description

Technical Field

[0001] This application relates to the fields of vehicle engineering and electrical connection technology, and in particular to a frame-type vehicle frame grounding conduction structure and vehicle. Background Technology

[0002] With the rapid development of new energy heavy-duty trucks towards larger battery capacities and longer driving ranges, the traditional integrated straight-through longitudinal beam frame structure is facing significant changes. To accommodate the layout requirements of large-capacity battery packs, the industry is gradually adopting a modular, multi-section frame structure, as shown in the attached diagram. Figure 1 As shown, this new type of frame, through the combination of segmented longitudinal beams and cross beams, allows for flexible adjustment of the battery pack placement space.

[0003] Meanwhile, in terms of anti-corrosion technology, to meet the anti-corrosion requirements of new energy heavy trucks under complex working conditions, the chassis manufacturing process has shifted from the traditional overall electrophoresis to the more advanced "part electrophoresis + assembly powder coating" technology. Taking Foton Changsha Super Truck Plant as an example, it adopts a process of segmented electrophoresis followed by reassembly, combined with powder coating treatment of the chassis assembly, to achieve a double 1000-hour salt spray resistance and aging resistance, realizing a 15-year rust-free protection effect. However, this process also brings new technical challenges. The electrophoretic layer forms an insulating barrier at the segment joint surface, resulting in a significant increase in the resistance between different sections of the chassis (measured to be above 10mΩ). Consequently, the different sections of the chassis are no longer low-impedance conductors, failing to meet the basic requirements of single-wire automotive wiring harnesses.

[0004] To meet the basic requirements of a single-wire system in automobiles, the industry generally uses a conductive ground wire harness to conduct wires through the vehicle frame (as shown in the attached diagram). Figure 2 As shown, this method has the following problems:

[0005] 1. Connecting grounding harnesses to different parts of the vehicle frame increases the vehicle's weight and cost;

[0006] 2. The electrical systems of new energy heavy truck chassis have high power requirements, and the grounding wiring harnesses require large diameters, occupying a lot of space and making assembly difficult.

[0007] 3. The grounding wiring harnesses connecting different parts of the vehicle frame can affect the vehicle's aesthetics to some extent. Utility Model Content

[0008] To address the shortcomings of existing technologies, this utility model provides a frame-type vehicle frame grounding and conduction structure and vehicle. It completes the grounding and conduction of the disassembled electrophoretic vehicle frame without adding any new parts, and has the advantages of low cost, easy operation and process compatibility. The redundant design ensures the stability of the electrical system, and the structure can be extended to other frame-type vehicle structures to meet the needs of multiple scenarios.

[0009] To achieve the above objectives, the first aspect of this utility model provides a frame-type vehicle frame grounding and conduction structure, including at least one set of interconnected metal components. The connection points of the metal components are connected by at least one set of double-bolt redundant units. The double-bolt redundant units used to achieve mechanical fastening and electrical conduction include two parallel grounding bolts, and the surface of the grounding bolts is provided with a zinc-nickel alloy plating layer.

[0010] Furthermore, the grounding bolts are also coated with an anti-corrosion layer.

[0011] Furthermore, the metal component has an L-shaped or T-shaped structure and is provided with through holes. The through holes are obtained by scraping paint with a paint scraper, and the grounding bolts complete the mechanical fastening of the metal component through the through holes.

[0012] Furthermore, when the metal component has an L-shaped structure, the metal component includes a first segment beam and a second segment beam. The first segment beam is connected to the second segment beam as a whole through spatially separated double-bolt redundant units, forming a parallel conductive path.

[0013] Furthermore, when the metal component has a T-shaped structure, the metal component includes a first segmented beam, a second segmented beam, and a third segmented beam. A first set of double-bolt redundant units is provided at the connection between the first segmented beam and the second segmented beam, and a second set of double-bolt redundant units is provided at the connection between the second segmented beam and the third segmented beam. The first set of double-bolt redundant units and the second set of double-bolt redundant units together constitute a four-node conductive network, and each set of double-bolt redundant units independently forms a parallel conductive path.

[0014] Furthermore, the contact resistance of the grounding bolt is ≤0.5mΩ.

[0015] Furthermore, the contact resistance between the segmented beams in the metal component is ≤10mΩ.

[0016] Furthermore, the grounding conduction structure is a split structure that can be disassembled and reassembled.

[0017] Furthermore, the grounding conduction structure also includes multiple structural bolts for mechanical connection.

[0018] The second aspect of this utility model provides a vehicle, which is a frame-type structure vehicle, and the vehicle is provided with the aforementioned frame-type frame grounding and conduction structure.

[0019] The beneficial technical effects of this utility model are as follows:

[0020] This invention replaces some structural bolts (ordinary bolts) at the connection points of metal components in the grounding and conductive structure with conductive grounding bolts, thereby achieving low impedance requirements in different parts of the vehicle frame. Furthermore, the zinc-nickel alloy plating and anti-corrosion layer on the surface of the grounding bolts can meet the requirements for corrosion resistance, conductivity, and economy.

[0021] The grounding bolt of this utility model serves both mechanical fastening and electrical conduction functions, avoiding the increase in cost and complexity due to additional grounding wire harnesses; and the metal component connection adopts a double bolt redundant unit, constructing multiple parallel conduction paths in different areas of the frame, thereby improving fault tolerance. Attached Figure Description

[0022] The accompanying drawings, incorporated in and forming part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application. It is obvious that the drawings described below are merely some embodiments of this application, and those skilled in the art can obtain other drawings based on these drawings without any inventive effort. In the drawings:

[0023] Figure 1 This is a schematic diagram of an existing multi-segment frame structure.

[0024] Figure 2 A conductive frame that uses a conductive grounding harness in existing technology;

[0025] Figure 3 This is an exemplary assembly drawing of a metal component for this application;

[0026] Figure 4 This is another exemplary assembly drawing of a metal component in this application.

[0027] Figure Labels

[0028] 1: First segment beam; 2: Second segment beam; 3: Third segment beam; 4: Ground bolt; 5: Double bolt redundant unit. Detailed Implementation

[0029] Unless otherwise defined, all technical and / or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. It should be understood that certain features of this invention (described in the context of separate embodiments for clarity) may also be provided in combination in a single embodiment. Conversely, multiple features of this invention (described in the context of a single embodiment for brevity) may also be provided separately or in any suitable combination or, where appropriate, in any other described embodiment of this invention. Certain features described in the context of various embodiments will not be considered essential features of those embodiments unless the embodiment is inoperable without those elements. The present invention is further illustrated below by specific examples; however, it should be noted that the specific process conditions and results described in the embodiments of this invention are for illustrative purposes only and should not be construed as limiting the scope of protection of this invention. All equivalent changes or modifications made in accordance with the spirit and essence of this invention should be covered within the scope of protection of this invention.

[0030] First, it should be noted that the materials used for the plating or coating on the surface of the grounding bolt 4 in this application are all commercially available materials, and the plating process, coating process and paint removal process are all existing technologies. This application does not involve any improvement to the materials or process methods.

[0031] like Figure 3 and Figure 4 As shown, this utility model provides a frame-type vehicle frame grounding and conduction structure, including at least one set of interconnected metal components. The connection of the metal components is connected by at least one set of double-bolt redundant units 5. The double-bolt redundant unit 5 used to achieve mechanical fastening and electrical conduction includes two parallel grounding bolts 4, and the surface of the grounding bolts 4 is provided with a zinc-nickel alloy plating layer.

[0032] Furthermore, to meet the requirements of corrosion resistance, electrical conductivity, and economy, this application applies a plating layer to the surface of the grounding bolt 4, and conducts comparative tests on the plating materials to select the optimal solution. The comparative test results are shown in Table 1 below:

[0033] Table 1. Coating Types and Their Performance Tests

[0034] Coating type electrical conductivity Corrosion resistance cost Zinc plating 4 points 2 points 3 points Dacromet 3 points 5 points 3 points Zinc-nickel alloy 4 points 5 points 4 points silver 5 points 3 points 5 points

[0035] (Table 1 uses a scoring system; the higher the score, the better the performance.)

[0036] As shown in Table 1, the zinc-nickel alloy plating is the optimal solution. Furthermore, this application does not specifically limit the thickness of the zinc-nickel alloy plating, but sets it according to actual needs, such as a plating thickness of 8μm to 12μm.

[0037] Furthermore, this application employs a dual-bolt redundant unit 5, with two parallel ground bolts 4 forming a redundant path through parallel arrangement. When a single ground bolt 4 fails due to vibration, corrosion, or other reasons, the remaining ground bolts 4 can still maintain the integrity of the conductive path. During mechanical fastening, the two ground bolts 4 can share the load, reducing stress concentration at a single point and improving the shear resistance of the metal component connection, making it particularly suitable for dynamic loads under high torque conditions in new energy heavy-duty trucks. In addition, the dual-bolt redundant unit 5 of this application can form a parallel conductive path, effectively reducing the current density at a single point, reducing the temperature rise of the contact surface, and optimizing current distribution. The combination of the dual-bolt redundant unit 5 and the zinc-nickel alloy plating in this application can resolve the contradiction between conductivity and corrosion protection in segmented vehicle frames.

[0038] Furthermore, the grounding bolt 4 of this application is also provided with an anti-corrosion layer. This anti-corrosion layer can be conductive grease or other anti-corrosion materials applied to the grounding bolt 4. This application does not specifically limit the anti-corrosion material; it can be selected according to actual needs, such as UV-cured anti-corrosion adhesive, elastic coating adhesive, polymer protective adhesive, etc. This application utilizes the anti-corrosion layer and the zinc-nickel alloy plating to achieve synergistic optimization, solving the grounding failure problem caused by the insulation of the transmission anti-corrosion coating, which is superior to a single plating solution; and ensuring that the grounding bolt 4 maintains stable conductivity during vehicle operation.

[0039] Furthermore, the metal component has an L-shaped or T-shaped structure and is provided with through holes. These through holes are obtained by scraping away paint with a paint scraper, and the grounding bolt 4 mechanically fastens the metal component through these through holes. This application removes the paint from the through holes, breaking down the electrophoretic insulation barrier. If the grounding bolt 4 were installed directly without removing the paint, the contact resistance would increase significantly. After paint scraping, the base metal is exposed, establishing an effective conductive path. This application also conducted comparative tests on different paint removal schemes to select the optimal scheme. The comparative test results are shown in Table 2 below.

[0040] Table 2 Paint Removal Solutions and Performance Tests

[0041] Paint removal solution reliability consistency cost Paint scraper 4 points 5 points 5 points sticker cover 2 points 2 points 3 points Bolt cover 3 points 3 points 2 points

[0042] (Table 2 uses a scoring system; the higher the score, the better the performance.)

[0043] As shown in Table 2, the consistency of the test using the masking method is poor, and the best method is to use a paint scraper to scrape the paint.

[0044] Furthermore, such as Figure 3As shown, when the metal component has an L-shaped structure, the metal component includes a first segment beam 1 and a second segment beam 2. The first segment beam 1 is connected to the second segment beam 2 as a whole through a spatially separated double-bolt redundant unit 5, forming a parallel conductive path. In this application, the two ground bolts 4 of the double-bolt redundant unit 5 are redundant with each other, resulting in high reliability.

[0045] Furthermore, such as Figure 4 As shown, when the metal component has a T-shaped structure, it includes a first segmented beam 1, a second segmented beam 2, and a third segmented beam 3. A first set of double-bolt redundant units 5 is provided at the connection between the first segmented beam 1 and the second segmented beam 2, and a second set of double-bolt redundant units 5 is provided at the connection between the second segmented beam 2 and the third segmented beam 3. The first and second sets of double-bolt redundant units 5 together constitute a four-node conductive network, with each set of double-bolt redundant units 5 independently forming a parallel conductive path. This application's T-shaped metal component upgrades the frame from a passive conductor to an active current distribution network, achieving a dual balanced distribution of stress and current through the first and second sets of double-bolt redundant units 5.

[0046] Furthermore, after the completion of the segmented electrophoretic assembly of the frame, the grounding conduction structure of this application underwent resistance testing. A high-precision and easy-to-operate "micro-ohmmeter" device was used for testing. The test results showed that the contact resistance of the grounding bolt 4 of this application was ≤0.5mΩ; and the contact resistance between the segmented beams in the metal components was ≤10mΩ.

[0047] Furthermore, the grounding conduction structure is a modular structure that can be disassembled and reassembled. This application achieves the modular structure through segmented beams and grounding bolts 4, which facilitates installation and maintenance, provides high redundancy and fault tolerance, high reliability, and low cost.

[0048] Furthermore, the grounding conduction structure also includes multiple structural bolts for mechanical connection. The structural bolts in this application are designed to bear mechanical loads (such as shear force and vibration load), while the grounding bolt 4 is also used for electrical conduction; their functions are clearly defined. Moreover, the detachable nature of the structural bolts allows for individual replacement of damaged components without disrupting the overall grounding conduction network. The structural bolts and grounding bolt 4 form a dual protection system; even if the grounding bolt 4 fails due to corrosion, the structural bolts can still maintain the mechanical connection, preventing structural disintegration.

[0049] Furthermore, the grounding conduction structure of this application can ensure that the contact resistance between various components of the frame meets the design requirements of a single-wire harness, matches the electrophoresis process of the frame components, and does not require changes to the existing production process; the grounding conduction of the electrophoresis frame components is completed without adding any new parts, which has the advantages of low cost, easy operation and process compatibility, and the redundant design ensures the stability of the electrical system.

[0050] This application also provides a vehicle, which is a frame-type structure vehicle such as a new energy heavy truck, electric construction machinery, hydrogen-powered heavy truck, etc., and the vehicle is equipped with the aforementioned frame-type chassis grounding and conduction structure to adapt to multiple scenario requirements.

[0051] The above embodiments are merely illustrative of the principles and effects of this utility model and are not intended to limit the scope of this utility model. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this utility model. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this utility model should still be covered by the claims of this utility model.

Claims

1. A frame-type vehicle frame grounding and conductive structure, characterized in that, It includes at least one set of interconnected metal components, the connection of which is connected by at least one set of double bolt redundant units (5). The double bolt redundant units (5) used to achieve mechanical fastening and electrical conduction include two parallel ground bolts (4), and the surface of the ground bolts (4) is provided with a zinc-nickel alloy plating.

2. The frame-type vehicle frame grounding and conductive structure according to claim 1, characterized in that, The grounding bolt (4) is also provided with an anti-corrosion layer.

3. The frame-type vehicle frame grounding and conductive structure according to claim 1 or 2, characterized in that, The metal component has an L-shaped or T-shaped structure and is provided with a through hole. The through hole is obtained by scraping paint with a paint scraper. The grounding bolt (4) completes the mechanical fastening of the metal component through the through hole.

4. The frame-type vehicle frame grounding and conductive structure according to claim 3, characterized in that, When the metal component has an L-shaped structure, the metal component includes a first segment beam (1) and a second segment beam (2). The first segment beam (1) is connected to the second segment beam (2) by the spatially separated double bolt redundant unit (5) to form a parallel conduction path.

5. The frame-type vehicle frame grounding and conductive structure according to claim 3, characterized in that, When the metal component is T-shaped, the metal component includes a first segmented beam (1), a second segmented beam (2), and a third segmented beam (3). A first set of double-bolt redundant units (5) is provided at the connection between the first segmented beam (1) and the second segmented beam (2), and a second set of double-bolt redundant units (5) is provided at the connection between the second segmented beam (2) and the third segmented beam (3). The first set of double-bolt redundant units (5) and the second set of double-bolt redundant units (5) together constitute a four-node conductive network, and each set of double-bolt redundant units (5) independently forms a parallel conductive path.

6. The frame-type vehicle frame grounding and conductive structure according to claim 4 or 5, characterized in that, The contact resistance of the grounding bolt (4) is ≤0.5mΩ.

7. The frame-type vehicle frame grounding and conductive structure according to claim 6, characterized in that, The contact resistance between the segmented beams in the metal component is ≤10mΩ.

8. The frame-type vehicle frame grounding and conductive structure according to claim 7, characterized in that, The grounding conduction structure is a split structure that can be disassembled and reassembled.

9. The frame-type vehicle frame grounding and conductive structure according to claim 8, characterized in that, The grounding and conductive structure also includes multiple structural bolts for mechanical connection.

10. A vehicle, characterized in that, The vehicle is a frame-type structure vehicle, and the vehicle is provided with a frame-type frame grounding and conductive structure as described in any one of claims 1 to 9.

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