How to replace the front structure and brake actuator of a frame vehicle

Abstract

To provide a front structure of a body-on-frame vehicle that allow an easy replacement of a brake actuator.SOLUTION: A front structure 50 of a body-on-frame vehicle 100 includes: a pair of left and right side rails 11L, 11R extending in a vehicle front-rear direction; cross-members 12a, 12b extending in a vehicle width direction and coupling the side rails 11L, 11R together; a motor 2 for traveling disposed between the cross-members 12a, 12b; and a brake actuator 6 disposed on a vehicle rear side relative to the cross-member 12b and disposed on an inner side in the vehicle width direction relative to the side rail 11R. The front structure is configured such that, when the motor 2 is removed, a worker is able to access the brake actuator 6 from a space between the cross-members 12a, 12b.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a front structure of a frame vehicle and a method for replacing a brake actuator. [Background technology]

[0002] Conventionally, a brake actuator that is disposed between a master cylinder and a wheel brake and controls the hydraulic pressure supplied to the wheel brake is known (see, for example, Patent Document 1). This brake actuator is disposed in the engine compartment and attached to a corner where an apron side member and a dash cross member are joined. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2001-180467 A Summary of the Invention [Problem to be solved by the invention]

[0004] Here, when the above-mentioned brake actuator is mounted on a frame vehicle, it is desirable that the brake actuator can be easily replaced by an operator.

[0005] The present invention has been made to solve the above-mentioned problems, and an object of the present invention is to provide a front structure of a frame vehicle that makes it easy to replace a brake actuator, and a method for replacing a brake actuator. [Means for solving the problem]

[0006] The front structure of a frame vehicle according to the present invention comprises a pair of left and right side rails extending in the fore-and-aft direction of the vehicle, a first cross member extending in the vehicle width direction to connect the side rails, and a second cross member arranged on the rear side of the vehicle from the first cross member and extending in the vehicle width direction to connect the side rails. The front structure of a frame vehicle comprises a power source for traveling arranged between the first cross member and the second cross member, and a brake actuator arranged on the rear side of the vehicle from the second cross member and on the inside in the vehicle width direction from the side rails, and is configured so that when the power source is removed, an operator can access the brake actuator from the space between the first cross member and the second cross member.

[0007] By configuring it in this manner, after the power source is removed, an operator can enter the space between the first cross member and the second cross member to access the brake actuator, making it easier to replace the brake actuator.

[0008] The front structure of the above-mentioned frame vehicle may include a mounting portion to which the brake actuator is attached using a fastening member, a first support portion connected to the rear surface of the second cross member and supporting the mounting portion, and a second support portion connected to the inner surface of the side rail and supporting the mounting portion, and may be configured so that when the power source is removed, an operator can access the fastening member from the space between the first cross member and the second cross member.

[0009] In this case, the system may be provided with a pipe fitting arranged in the flow path from the master cylinder to the brake actuator and attached to the second support portion, one end of the pipe fitting is connected to a first pipe extending from the master cylinder, and the other end of the pipe fitting is connected to a second pipe extending from the brake actuator to the rear side of the vehicle, and when the power source is removed, the first connection portion between the second pipe and the pipe fitting may be configured to be accessible by an operator from the space between the first cross member and the second cross member.

[0010] In the front structure of the above-mentioned frame vehicle, the third piping extending from the brake actuator to the wheel brake is arranged to extend upward from the top of the brake actuator, and when the power source is removed, the second connection portion between the third piping and the brake actuator may be configured to be accessible by an operator from the space between the first cross member and the second cross member.

[0011] In the above-mentioned front structure of the frame vehicle, the power source may include a motor, a battery that stores electricity to drive the motor may be arranged on the rear side of the vehicle of the second cross member, and a cooling pipe for cooling the battery may be arranged on the vehicle widthwise inside of the brake actuator.

[0012] The method for replacing a brake actuator according to the present invention is a method for replacing a brake actuator provided on a frame vehicle. The frame vehicle includes a pair of left and right side rails extending in the front-rear direction of the vehicle, a first cross member extending in the vehicle width direction to connect the side rails, a second cross member disposed on the vehicle rear side of the first cross member and extending in the vehicle width direction to connect the side rails, a power source for traveling disposed between the first cross member and the second cross member, and a brake actuator disposed on the vehicle rear side of the second cross member and on the vehicle width inner side of the side rails. The method for replacing the brake actuator includes the steps of removing the power source, an operator entering a space between the first cross member and the second cross member, and the operator having entered the space between the first cross member and the second cross member accessing the brake actuator.

[0013] By configuring it in this manner, after the power source is removed, an operator can enter the space between the first cross member and the second cross member to access the brake actuator, making it easier to replace the brake actuator. Effect of the Invention

[0014] According to the front structure of a frame vehicle and the method of replacing a brake actuator of the present invention, the brake actuator can be easily replaced. [Brief description of the drawings]

[0015] [Figure 1] 1 is a plan view showing a frame vehicle according to an embodiment of the present invention; [Diagram 2] FIG. 2 is a perspective view showing a frame structure of the frame vehicle of FIG. 1. [Diagram 3] FIG. 3 is an enlarged view of a brake actuator attached to the frame of FIG. 2. [Figure 4] FIG. 4 is a bottom view of the brake actuator of FIG. 3. [Diagram 5] 13 is a diagram showing the state in which a worker has entered the space between the cross members after the motor has been removed from the frame structure. [Figure 6] FIG. 6 is a diagram showing a state in which a piping is removed from a brake actuator using a flare nut wrench, showing an example as viewed by the worker in FIG. 5. [Figure 7] FIG. 13 illustrates the pipe being removed from the pipe fitting using a flare nut wrench. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] Hereinafter, one embodiment of the present invention will be described.

[0017] First, an outline of a frame vehicle 100 to which a front structure 50 according to one embodiment of the present invention is applied will be described with reference to Fig. 1. In Fig. 1 and other figures, the X1 direction is the front side of the vehicle, the X2 direction is the rear side of the vehicle, the Y1 direction is the left side, and the Y2 direction is the right side.

[0018] The frame vehicle 100 comprises a frame skeleton 1 and a cabin (not shown), with the cabin mounted on the frame skeleton 1. For example, the cabin is entirely mounted on the frame skeleton 1, and the frame vehicle 100 is not provided with an engine hood or a cab tilt mechanism. As shown in Fig. 1, the frame vehicle 100 also comprises a motor 2, a battery 3, a cooling device including a radiator 4, a steering device including a steering gear 5, and a brake device including a brake actuator 6. The motor 2 is an example of a "power source" in the present invention.

[0019] The motor 2 is provided to output driving force for driving the vehicle. The battery 3 is chargeable and dischargeable, and is configured to store power for driving the motor 2. The cooling device is provided to cool the motor 2 and the battery 3. The cooling device is configured to circulate a cooling medium between the radiator 4 and the motor 2 and the battery 3 by a pump (not shown). The radiator 4 is provided to cool the cooling medium by heat exchange with outside air. The steering device is provided to adjust the steering angle of the left front wheel 7FL and the right front wheel 7FR.

[0020] The braking device includes a master cylinder (not shown), wheel brakes (not shown) arranged on each wheel (left front wheel 7FL, right front wheel 7FR, left rear wheel 7RL, and right rear wheel 7RR), and a brake actuator 6 arranged between the master cylinder and the wheel brakes. The master cylinder is configured to supply hydraulic pressure to the brake actuator 6 during braking. The brake actuator 6 is provided to control the hydraulic pressure supplied to each wheel brake during braking. Each wheel brake is, for example, a disc brake or a drum brake, and is configured to generate a braking force according to the hydraulic pressure supplied thereto.

[0021] The frame structure 1 includes side rails 11L and 11R and cross members 12a to 12e. The side rails 11L and 11R are formed to extend in the vehicle front-rear direction (X1 and X2 directions) and are provided in a pair on the left and right. The side rails 11L and 11R are arranged to face each other in the vehicle width direction (Y1 and Y2 directions), with the side rail 11L arranged on one side (left side) in the vehicle width direction and the side rail 11R arranged on the other side (right side) in the vehicle width direction. The cross members 12a to 12e are formed to extend in the vehicle width direction and are configured to connect the side rails 11L and 11R. The cross members 12a to 12e are arranged at intervals in the vehicle front-rear direction. The cross members 12a and 12b are arranged on the vehicle front side, and the cross members 12c to 12e are arranged on the vehicle rear side. The cross members 12a and 12b are examples of the "first cross member" and the "second cross member" in the present invention, respectively.

[0022] Here, the front structure 50 of the frame vehicle 100 includes side rails 11L, 11R, cross members 12a, 12b, a motor 2, and a brake actuator 6. The cross member 12a is the cross member disposed closest to the front of the vehicle, and the cross member 12b is the cross member disposed second from the front of the vehicle. In other words, the cross member 12b is disposed on the rear side of the vehicle relative to the cross member 12a. The motor 2 is disposed between the cross members 12a and 12b when viewed in a plan view.

[0023] Moreover, the radiator 4 is disposed further forward of the motor 2 in a plan view. The steering gear 5 is disposed further rearward of the motor 2 in a plan view. The battery 3 is provided in most of the central portion in the longitudinal direction of the vehicle in a plan view. Therefore, the battery 3 is disposed on the rear side of the cross member 12b. A cooling pipe 41 (see FIG. 6), which is a passage for the cooling medium of the cooling device, is connected to the battery 3. The cooling pipe 41 is provided to cool the battery 3, and is disposed inside the brake actuator 6 in the vehicle width direction.

[0024] -Brake Actuator- Next, the structure of the brake actuator 6 in the front structure 50 of this embodiment will be described with reference to FIGS.

[0025] As shown in Fig. 2, the brake actuator 6 is attached to the rear surface (surface facing the rear of the vehicle) of the cross member 12b and the inner surface of the side rail 11R. Therefore, the brake actuator 6 is disposed on the rear side of the vehicle with respect to the cross member 12b, and is disposed on the inner side in the vehicle width direction with respect to the side rail 11R. Therefore, when the motor 2 (see Fig. 1) is removed, the worker W (see Fig. 5) can access the brake actuator 6 from the space between the cross members 12a and 12b.

[0026] As shown in Fig. 3, the brake actuator 6 is attached to the frame 1 using a bracket 8. The bracket 8 has a mounting portion 81 to which the brake actuator 6 is attached, and support portions 82 to 84 that support the mounting portion 81. The support portions 82 and 83 are examples of a "first support portion" in the present invention, and the support portion 84 is an example of a "second support portion" in the present invention.

[0027] The mounting portion 81 is formed in a plate shape so that the brake actuator 6 can be placed thereon. The brake actuator 6 is attached to the mounting portion 81 via a bushing by bolts 811. For example, as shown in FIG. 4, the brake actuator 6 is attached to the mounting portion 81 using three bolts 811. One of the three bolts 811 is disposed on the bottom surface of the brake actuator 6, and two of the three bolts 811 are disposed near the lower end of the rear surface (surface toward the rear of the vehicle) of the brake actuator 6. The bolts 811 are an example of a "fastening member" in the present invention.

[0028] The support portion 82 is disposed on the inner side in the vehicle width direction relative to the support portions 83 and 84. One end of the support portion 82 is joined to the lower surface of the mounting portion 81. The other end of the support portion 82 is connected to the rear surface of the cross member 12b by a bolt 821. The other end of the support portion 82 is disposed on the inner side in the vehicle width direction relative to the brake actuator 6.

[0029] The support portion 83 is disposed on the vehicle front side with respect to the support portion 84. One end of the support portion 83 is joined to the lower surface of the mounting portion 81. The other end of the support portion 83 is connected to the rear surface of the cross member 12b by a bolt 831. The other end of the support portion 83 is disposed on the outer side with respect to the brake actuator 6 in the vehicle width direction.

[0030] The support portion 84 is formed by assembling plate materials 84a and 84b. One end of the support portion 84 is joined to the lower surface of the attachment portion 81. The other end of the support portion 84 is connected to the inner surface of the side rail 11R by a bolt 841. The other end of the support portion 84 is disposed outward in the vehicle width direction relative to the brake actuator 6, and is disposed rearward of the other end of the support portion 82 and the other end of the support portion 83.

[0031] The brake actuator 6 includes an actuator body (not shown) that controls the hydraulic pressure supplied to each wheel brake, and an ECU (not shown) that controls the actuator body. As shown in Fig. 3, the brake actuator 6 is provided with a connector 61 for connecting a wire harness (not shown) for communication with the ECU. For example, two flow paths from the master cylinder are connected to the actuator body, and four flow paths leading to each wheel brake are connected to the actuator body.

[0032] The two flow paths from the master cylinder to the brake actuator 6 are each composed of a pipe 91, a pipe joint 92, and a pipe 93. The pipe 91 is formed so as to extend from the master cylinder to the rear of the vehicle along the side rail 11R. The pipe joint 92 is provided to connect the pipes 91 and 93. Specifically, the pipe 91 extending from the master cylinder is connected to one end of the pipe joint 92, and the pipe 93 extending from the rear surface of the brake actuator 6 to the rear side of the vehicle is connected to the other end of the pipe joint 92. The two pipe joints 92 are connected by a connecting plate 921, and the connecting plate 921 is attached to the middle part of the support part 84 by a bolt 922. That is, the support part 84 also has a function of supporting the two pipe joints 92. The two pipe joints 92 are arranged on the rear side of the brake actuator 6 and on the outer side of the brake actuator 6 in the vehicle width direction. The pipes 91 and 93 are examples of the "first pipe" and the "second pipe" of the present invention, respectively.

[0033] The four flow paths from the brake actuator 6 to each wheel brake are each formed by a pipe 94. The pipe 94 is formed so as to extend upward from the upper surface of the brake actuator 6 to each wheel brake. The pipe 94 to the wheel brake of the left front wheel 7FL (see FIG. 1) is formed so as to extend from the brake actuator 6 to the left along the cross member 12b, and then extend to the front of the vehicle along the side rail 11L (see FIG. 1). The pipe 94 to the wheel brake of the left rear wheel 7RL (see FIG. 1) is formed so as to extend from the brake actuator 6 to the left along the cross member 12b, and then extend to the rear of the vehicle along the side rail 11L. The pipe 94 to the wheel brake of the right front wheel 7FR (see FIG. 1) is formed so as to extend from the brake actuator 6 to the front of the vehicle along the side rail 11R. The pipe 94 to the wheel brake of the right rear wheel 7RR (see FIG. 1) is formed so as to extend from the brake actuator 6 to the rear of the vehicle along the side rail 11R. The pipe 94 is an example of the "third pipe" of the present invention.

[0034] -How to replace the brake actuator- 5 to 7, a method for replacing the brake actuator 6 in the front structure 50 of this embodiment will be described. The brake actuator 6 is replaced when the motor 2 and the steering gear 5 are replaced periodically.

[0035] First, the motor 2 and the steering gear 5 are removed from the frame structure 1. As a result, a space is formed between the cross members 12a and 12b into which the worker W can enter. Then, as shown in Fig. 5, the worker W enters the space between the cross members 12a and 12b from below the frame structure 1 into which the motor 2 and the like were located. This worker W can access the brake actuator 6 attached to the rear surface of the cross member 12b and the inner surface of the side rail 11R.

[0036] Specifically, the worker W can access, from the space between the cross members 12a and 12b, the wire harness (not shown) connected to the connector 61, the flare nut 94a connecting the pipe 94 to the brake actuator 6, the flare nut 92a connecting the pipe 93 to the pipe joint 92, and the bolt 811 for attaching the brake actuator 6 to the bracket 8. The flare nuts 92a and 94a are examples of the "first connecting portion" and the "second connecting portion" of the present invention, respectively.

[0037] Here, since the cooling pipes 41 are arranged on the inner side of the brake actuator 6 in the vehicle width direction, as shown in Fig. 6, the view of the worker W is partially obstructed, but the brake actuator 6 can be seen through the gaps in the cooling pipes 41. Then, the worker W enters the space between the cross members 12a and 12b and performs the work of removing the brake actuator 6.

[0038] First, the worker W removes the wire harness from the connector 61. Next, the worker W sequentially releases the fastening of the four flare nuts 94a using the flare nut wrench 150. That is, the four pipes 94 are sequentially removed from the brake actuator 6. Note that Wh in FIG. 6 indicates the hand of the worker W holding the flare nut wrench 150.

[0039] 7, the worker W sequentially releases the fastening of the two flare nuts 92a using the flare nut wrench 150. That is, the two pipes 93 are sequentially removed from the pipe joint 92. For this reason, in this embodiment, the pipe 93 is removed together with the brake actuator 6. This is because, in a state in which the brake actuator 6 is attached to the frame structure 1, it is difficult to perform the task of releasing the fastening of the flare nut 93a connecting the pipe 93 to the brake actuator 6. That is, it is difficult to ensure a space for swinging the flare nut wrench 150 to release the fastening of the flare nut 93a.

[0040] Then, the worker W uses a jig (not shown) to sequentially release the fastening of the three bolts 811. Next, the worker W removes the brake actuator 6 from the bracket 8. In this manner, the removal work of the brake actuator 6 is completed.

[0041] Thereafter, the worker W enters the space between the cross members 12a and 12b and performs the installation work of a new brake actuator (not shown). This installation work is performed in the reverse order of the removal work.

[0042] -effect- In this embodiment, as described above, the motor 2 is provided between the cross members 12a and 12b, and the brake actuator 6 is attached to the rear surface of the cross member 12b and the inner surface of the side rail 11R, so that after removing the motor 2, the worker W can enter the space between the cross members 12a and 12b to access the brake actuator 6, making it easy to replace the brake actuator 6 even in a frame vehicle 100 that is not provided with an engine hood or cab tilt mechanism. Also, because the brake actuator 6 is located behind the crushable zone, the brake actuator 6 is less likely to be damaged in the event of a vehicle collision.

[0043] In addition, in this embodiment, the bracket 8 is attached to the frame 1, and the brake actuator 6 is attached to the bracket 8 by the bolt 811, so that the brake actuator 6 can be removed from the bracket 8 by releasing the fastening of the bolt 811.

[0044] Furthermore, in this embodiment, a pipe joint 92 is provided in the flow path from the master cylinder to the brake actuator 6, and by releasing the fastening of the flare nut 92a, the pipe 93 can be removed from the pipe joint 92. Therefore, the brake actuator 6 can be removed together with the pipe 93. In other words, the brake actuator 6 can be removed without releasing the fastening of the flare nut 93a.

[0045] In this embodiment, piping 94 is provided extending from the brake actuator 6 to each wheel brake. The piping 94 can be removed from the brake actuator 6 by releasing the fastening of the flare nut 94a.

[0046] In addition, in this embodiment, the cooling pipes 41 are disposed on the inner side of the brake actuator 6 in the vehicle width direction, so that the brake actuator 6 can be seen through the gaps in the cooling pipes 41.

[0047] Furthermore, in this embodiment, piping 91 is routed along the side rail 11R, and piping 94 is routed along the side rail 11R, the cross member 12b, and the side rail 11L, thereby simplifying the piping shape and reducing costs.

[0048] -Other embodiments- It should be noted that the embodiments disclosed herein are illustrative in all respects and are not intended to be limiting. Therefore, the technical scope of the present invention is not interpreted solely by the above-described embodiments, but is defined by the claims. The technical scope of the present invention includes all modifications within the scope and meaning equivalent to the claims.

[0049] For example, in the above embodiment, a motor 2 is shown as a power source for driving, but this is not limited to this. An internal combustion engine may be provided together with the motor as a power source for driving, or an internal combustion engine may be provided instead of the motor.

[0050] In addition, in the above embodiment, an example was shown in which the brake actuator 6 is attached to the rear surface of the cross member 12b and the inner surface of the side rail 11R, but this is not limited to the above, and the brake actuator may be attached to the rear surface of the cross member or the inner surface of the side rail.

[0051] Further, in the above embodiment, an example in which the pipe joint 92 is provided has been shown, but the present invention is not limited to this, and a pipe joint does not have to be provided as long as a working space for removing the pipes from the brake actuator can be secured.

[0052] In addition, in the above embodiment, an example is shown in which the piping 94 toward the wheel brake is arranged to extend upward from the upper surface of the brake actuator 6, but this is not limited to this, and the piping toward the wheel brake may be arranged to extend from other than the upper surface of the brake actuator (for example, from the side surface).

[0053] Further, in the above embodiment, an example has been shown in which the cooling pipe 41 is arranged on the inner side of the brake actuator 6 in the vehicle width direction, but this is not limiting, and the cooling pipe does not necessarily have to be arranged on the inner side of the brake actuator in the vehicle width direction.

[0054] In the above embodiment, a transmission that changes the speed of the motor output and a differential device that distributes the output of the transmission may be included within the case of the motor 2.

[0055] In addition, in the above embodiment, the order of the removal work of the brake actuator 6 is merely an example and is not limited to the above. [Industrial Applicability]

[0056] INDUSTRIAL APPLICABILITY The present invention can be used in a front structure of a frame vehicle and a method for replacing a brake actuator. [Explanation of symbols]

[0057] 2 Motor (power source) 3 Battery 6 Brake Actuator 11L, 11R side rails 12a Cross member (first cross member) 12b Cross member (second cross member) 41 Cooling piping 50 Front structure 81 Mounting part 82, 83 Support part (1st support part) 84 Support part (second support part) 91 Piping (First Piping) 92 Pipe fittings 92a Flare nut (first connection part) 93 Piping (Second Piping) 94 Piping (third piping) 94a Flare nut (second connection part) 100 frame car 811 Bolts (fastening members)

Claims

1. A pair of left and right side rails extending in the front-rear direction of the vehicle; a first cross member extending in a vehicle width direction and connecting the side rails; a second cross member disposed on a vehicle rear side with respect to the first cross member and extending in a vehicle width direction to connect the side rails, a power source for traveling disposed between the first cross member and the second cross member; a brake actuator disposed on a vehicle rear side with respect to the second cross member and on an inner side in a vehicle width direction with respect to the side rail, A front structure of a frame vehicle, characterized in that when the power source is removed, an operator can access the brake actuator from the space between the first cross member and the second cross member.

2. 2. The front structure of a frame vehicle according to claim 1, a mounting portion to which the brake actuator is attached using a fastening member; a first support portion connected to a rear surface of the second cross member and supporting the mounting portion; a second support portion connected to an inner surface of the side rail and supporting the mounting portion, A front structure of a frame vehicle, characterized in that when the power source is removed, an operator can access the fastening members from the space between the first cross member and the second cross member.

3. 3. The front structure of a frame vehicle according to claim 2, a pipe joint that is disposed in a flow path extending from a master cylinder to the brake actuator and is attached to the second support portion; A first pipe extending from the master cylinder is connected to one end of the pipe joint, A second pipe extending from the brake actuator toward the rear of the vehicle is connected to the other end of the pipe joint, A front structure of a frame vehicle, characterized in that when the power source is removed, the first connection portion between the second piping and the piping joint is accessible by an operator from the space between the first cross member and the second cross member.

4. 2. The front structure of a frame vehicle according to claim 1, a third pipe extending from the brake actuator toward the wheel brake is provided so as to extend upward from an upper portion of the brake actuator; A front structure of a frame vehicle, characterized in that when the power source is removed, the second connection portion between the third piping and the brake actuator is accessible by an operator from the space between the first cross member and the second cross member.

5. In the front structure of a frame vehicle according to any one of claims 1 to 4, the power source includes a motor; a battery that stores electric power to drive the motor is disposed on a vehicle rear side of the second cross member, A front structure of a frame vehicle, wherein a cooling pipe for cooling the battery is disposed on the inner side of the brake actuator in the vehicle width direction.

6. A method for replacing a brake actuator installed on a frame vehicle, comprising the steps of: The frame vehicle includes a pair of left and right side rails extending in the front-rear direction of the vehicle, a first cross member extending in the vehicle width direction and connecting the side rails, a second cross member arranged on the rear side of the vehicle relative to the first cross member and extending in the vehicle width direction and connecting the side rails, a power source for traveling arranged between the first cross member and the second cross member, and a brake actuator arranged on the rear side of the vehicle relative to the second cross member and on the inside of the side rails in the vehicle width direction, removing the power source; an operator entering a space between the first cross member and the second cross member; and a step of a worker entering a space between the first cross member and the second cross member accessing the brake actuator.

Images