Modular channel frame, method of fastening frame elements and device for its implementation

Abstract

FIELD: automotive engineering.SUBSTANCE: frame of a modular vehicle consists of a pair of parallel side members, the shelves of which are directed towards each other, with through structural and technological openings provided in them, connected to each other by several cross beams and a rear beam. The cross beams are made of sheet metal and are attached to the side members by means of a rigid detachable connection. Each side member has a channel cross-section and consists of at least two connected sections with different cross-section heights. Brackets for mounting the payload are attached to the outer surface of the side members. The stated problem is also solved by creating a device for threaded connection with zero clearance of frame elements and a method for fastening frame elements of a vehicle using this device.EFFECT: improved maintainability, ease of maintenance and overall reliability of the product are achieved.8 cl, 4 dwg

Description

[0001] The group of inventions relates to the field of automotive engineering, in particular, to modular designs of frames for light commercial vehicles, as well as to methods with means for fastening elements of such frames.

[0002] Traditional vehicle frame designs are known from prior art. They are made from metal sections of various shapes, typically rectangular or tubular. Such frames are most often manufactured using welded joints, which significantly limits the possibility of subsequent repair and replacement of individual components. The length of the frame cannot be adjusted to suit user needs and various operating conditions without compromising the integrity of the frame. The disadvantages of such frames include complexity of manufacture, the inability to modify, and poor repairability.

[0003] Also known from the prior art is a method for attaching a crossmember to a vehicle frame (US20160121929, publication number 20160121929, publication date 05 / 05 / 2016), according to which a projection is formed on the surface of the crossmember, which is installed into a hole or recess on the vehicle side member to form a locking connection. A disadvantage of the fastening method and means specified in the application is the complexity of manufacture and low maintainability. Damage or wear of the projections may make it impossible to reuse the element or increase the labor costs for its restoration.

[0004] A known truck frame design (CN115848496, publication number 115848496, publication date 03 / 28 / 2023) is selected as a prototype. The invention relates to a truck frame design consisting of a pair of side members, a plurality of cross beams installed between them, and a rear beam attached to the ends of the side members. All frame elements are equipped with standardized holes located at an equal distance and connected to each other by bolts and rivets. A disadvantage of this invention is the complexity of manufacture and low maintainability of the frame elements. Due to vibration and constant loads on the frame structure, the bolted connection may loosen, which will lead to loosening of the structure and a loss of rigidity.When using rivets, it is impossible to quickly repair the frame or replace part of the structure. Moreover, repairing damaged riveted joints often requires complete replacement of a section of the frame structure, which makes repairs an expensive and labor-intensive process.

[0005] The objective of this invention is to eliminate the above-mentioned drawbacks by creating an easy-to-manufacture modular frame design for light commercial vehicles that allows for length changes without significant configuration changes, quick replacement of individual components, thereby increasing maintainability, ease of maintenance and overall reliability of the product, while meeting the required levels of rigidity and strength of the structure.

[0006] Furthermore, the objective of the present invention is to create a threaded connection device and a method for connecting elements of a vehicle frame with zero clearance, ensuring maintainability and speed of assembly, reliable fixation of frame elements, increasing the stability of the structure to external mechanical loads, reducing the risk of fatigue cracks and deformations, and reducing the likelihood of play and vibrations.

[0007] The problem is solved by creating a modular vehicle frame consisting of a pair of parallel side members, the flanges of which are aligned toward each other and have through-holes for structural and technological purposes. These are connected by several cross members and a rear beam. The cross members are made of sheet metal and are attached to the side members via a rigid, detachable connection, forming a single horizontal plane. Each side member has a channel cross-section and consists of at least two connected sections with different cross-sectional heights: the height of one section is reduced relative to the other by an amount equal to twice the thickness of the material used.These parts are arranged in such a way as to form a mutually matching structure, ensuring precise alignment of the holes for subsequent attachment of the cross members. The cross members themselves are also provided with holes for rigidly mounting the payload. The side members are made of sheet metal and have a channel cross-section, and payload mounting brackets are attached to their outer surfaces, forming a single plane with the surface of the side members themselves. Additional holders for the vehicle's rear lights are installed where the rear beam attaches to the side members.

[0008] The problem is also solved by creating a zero-gap threaded connection device for frame components and a method for fastening vehicle frame components using this device. The device comprises a bolt, a threaded sleeve, and a spring washer. The threaded sleeve is shaped like a cylinder with two outer diameters, the smaller outer diameter of which corresponds to the nominal bore size in the connected parts and is shorter than the combined thickness of the connected parts. The larger outer diameter forms a flange with an end surface perpendicular to the sleeve axis, serving as a stop surface. The thread on the bolt corresponds to the internal thread of the sleeve.In the presented method, the holes of the mating frame elements are aligned, after which a threaded sleeve with a smaller outer diameter is installed in the resulting hole until the end surface of the flange contacts the frame element, a spring washer is installed on the reverse side of the hole, the bolt is gradually tightened and the clearance of the threaded connection is selected until the sleeve is completely fixed in the hole.

[0009] The technical results achieved by solving the set tasks are:

[0010] - creation of a modular frame design, which provides the ability to easily change the frame length and configuration, which improves maintainability and facilitates service maintenance.

[0011] - creation of a zero-gap threaded connection device and a method for fastening vehicle frame elements using this device, ensuring reliable adhesion of frame elements, resistant to mechanical impact, vibration and other adverse operating factors, by eliminating gaps between the hole and the threaded connection device, the wear resistance of the frame is increased, play and oscillatory movements between the elements are reduced, as a result of which fatigue cracks and deformations can form.

[0012] The essence of the claimed invention is explained by drawings, where:

[0013] Fig. 1 shows a general view of the frame;

[0014] Fig. 2 shows a top view of the frame.

[0015] Fig. 3 shows a zero-gap threaded connection device

[0016] Fig. 4 shows the threaded connection device assembled with the frame parts

[0017] The drawings indicate:

[0018] 1 - spar

[0019] 2 - through structural hole

[0020] 3 - through technological hole

[0021] 4 - cross beam

[0022] 5 - kerchief

[0023] 6 - rear beam

[0024] 7 - side member section

[0025] 8 - holes on the surface of the cross beams for rigid attachment of the payload

[0026] 9 - Rear light holders

[0027] 10 - brackets on the outer surface of the side members for mounting the payload

[0028] 11 - bolt

[0029] 12 - threaded sleeve

[0030] 13 - spring washer

[0031] 14 – collar.

[0032] The vehicle frame is a modular structure consisting of a pair of parallel side members 1, the flanges of which are oriented toward each other. They are provided with through structural openings 2 and service openings 3, which simplify the installation and replacement of necessary components and assemblies. The side members are connected by several cross members 4 and a rear beam. Each side member 1 has a channel cross-section and consists of at least two connected sections 7 with different cross-sectional heights: the height of one section is reduced relative to the other by an amount equal to twice the thickness of the material used. These parts are arranged in such a way as to form a mutually matching structure, ensuring precise alignment of service openings 3 for subsequent attachment of cross members 4.This design allows for varying the frame length and effectively configuring its configuration without compromising overall technical standards or design ergonomics. The cross members are made of sheet metal and are attached to the side members via gussets 5 and a rigid detachable connection, forming a single horizontal plane with them. Openings 8 for rigidly attaching the payload are provided on the surface of the cross members 4 themselves. Holders 9 for the vehicle's rear lighting are additionally installed where the rear beam attaches to the side members. Brackets 10 for mounting the payload are attached to the outer surface of the side members, forming a single plane with the surface of the side members 1 themselves.

[0033] The frame side members and cross members are made of sheet metal, significantly simplifying the manufacturing process and speeding up frame production. The structural elements are connected using a threaded connection. The frame itself is attached to the shortened integrated frame of the vehicle. After the frame is fully installed, its length is adjusted depending on the payload to be mounted on the frame, for example: an industrial van, a tanker, an open body, etc. The superstructure itself is installed on the frame using a crane or forklift, depending on the availability of the base (installation location). Next, the superstructure is bolted to pre-prepared mounting brackets, and the vehicle is ready for operation.If it is necessary to replace the superstructure with one that is larger and longer, prepare the installation site, unfasten the superstructures, disconnect the threaded connection device, lift the superstructure from the frame, remove the threaded connection devices at the side member attachment point (on each side), extend the frame to its maximum overall length, secure the frame sections with the threaded connection device, and space the attachment pads (mounting brackets) for the superstructure at the required distance, corresponding to the superstructure attachment points. Next, secure the pads (mounting brackets) with the threaded connection devices, install the superstructures (using a crane or forklift), secure the superstructures to the pads (mounting brackets) with the threaded connection device, and the vehicle is ready for operation.

[0034] A zero-gap threaded connection device comprises a bolt 11, a threaded sleeve 12, and a spring washer 13. The threaded sleeve 12 is shaped like a cylinder with two outer diameter steps, wherein the smaller outer diameter of the sleeve corresponds to the nominal size of the hole in the parts being joined and is shorter than the total thickness of the parts being joined, while the larger outer diameter forms a flange 14 with an end surface formed perpendicular to the axis of the threaded sleeve 12 and serving as a stop surface. The thread on the bolt 11 corresponds to the internal thread of the sleeve 12.Thus, when using this device, the effect of a riveted connection is achieved, which ensures the complete elimination of the gap between the parts, improves the strength and reliability of the connection, and reduces the impact of vibrations and mechanical loads. At the same time, the device can be easily dismantled outside the conditions of the production workshop, preserving the integrity of the connected parts and the possibility of reusing the connection without the need for its repair or restoration.

[0035] In this method, the holes of the mating frame elements are aligned, then a threaded bushing with a smaller outer diameter is installed into the resulting hole until the end surface of flange 14 contacts the frame element. Washer 13 is installed on the opposite side of the hole, bolt 11 is gradually tightened, and the threaded connection gap is adjusted until bushing 12 is fully secured in the hole. This ensures reliable contact between the elements, resistant to vibration and adverse operating conditions, increasing the durability of the structure and eliminating defects caused by gaps.

Claims

1. A vehicle frame consisting of side members with through structural and technological openings provided therein, connected to each other by several cross beams and a rear beam, characterized in that the vehicle frame is made modular, the cross beams are attached to the side members by means of a rigid detachable connection in such a way that they form a single horizontal plane, and the detachable connection is a threaded connection in which a threaded sleeve is used, made in the form of a cylinder with two steps of the outer diameter, where the smaller outer diameter of the sleeve corresponds to the nominal size of the hole in the parts being connected, and the larger outer diameter forms a flange with an end surface, wherein each side member has a channel section and consists of at least two connected sections,having different cross-section heights: the height of one section is reduced relative to the other by an amount equal to twice the thickness of the material used, these parts are arranged in such a way that they form a mutually matching structure, ensuring precise alignment of the technological holes for subsequent fastening of the cross beams, and holes are made on the surface of the cross beams themselves for rigid fastening of the payload.

2. The frame of a vehicle according to paragraph 1, characterized in that the side members are made of sheet metal.

3. The frame of a vehicle according to paragraph 1, characterized in that the side members have a channel section.

4. The frame of a vehicle according to paragraph 1, characterized in that the cross beams are made of sheet metal.

5. The frame of a vehicle according to paragraph 1, characterized in that holders for the rear lighting devices of the vehicle are additionally installed at the point where the rear beam is attached to the side members.

6. The frame of a vehicle according to paragraph 1, characterized in that brackets for mounting the payload are fixed along the outer surface of the side members, forming a single plane with the surface of the side members themselves.

7. A device for a zero-clearance threaded connection of frame elements according to paragraph 1, comprising a bolt, a threaded sleeve and a spring washer, wherein the thread on the bolt corresponds to the internal thread of the sleeve, characterized in that the threaded sleeve is made in the form of a cylinder with two steps of the outer diameter, wherein the smaller outer diameter of the sleeve corresponds to the nominal size of the hole in the parts being connected and is shorter than the total thickness of the parts being connected, and the larger outer diameter forms a flange with an end surface made perpendicular to the axis of the sleeve and serving as a stop surface.

8. A method for fastening elements of a vehicle frame using a device according to paragraph 2, in accordance with which the holes of the mating elements of the frame are aligned, after which a threaded sleeve with a smaller outer diameter is installed in the resulting hole until the end surface of the flange contacts the frame element, a spring washer is installed on the reverse side of the hole, the bolt is gradually tightened and the clearance of the threaded connection is selected until the sleeve is completely fixed in the hole.

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