ATV Frame Structure for Lightweight Strength and Stiffness
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Solution Overview
Problem
Existing all-terrain vehicles face challenges in achieving a lightweight frame that meets strength and stiffness requirements without compromising safety and stability, with existing solutions often increasing cost or failing to meet performance criteria.
Innovation Solution
The all-terrain vehicle features a frame design with optimized support positions and structures, including right and left upper and lower main beams, auxiliary main beams at angled tube portions, and pillars, along with specific mounting brackets and components like a cooling fan cover and rear suspension swing arm mount plates, made from high-strength materials like 20 CrMo steel, to enhance strength and reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If lightweight frame materials are used, then weight is reduced, but cost increases and strength/stability requirements may not be met
Solution Approach 1:
The frame is divided into multiple beam segments (upper main beams, lower main beams, auxiliary main beams) with distinct functions. Each segment is optimized independently for weight and strength, allowing the overall frame to achieve lightweight design while meeting structural requirements through coordinated segmentation of load-bearing paths.
Solution Approach 2:
The frame employs composite structural design combining multiple beam types (upper main beams, lower main beams, auxiliary main beams) made from high-strength materials. This composite approach allows different beam segments to work together, distributing loads efficiently and achieving both weight reduction and strength requirements that single-material designs cannot satisfy.
2Weight of moving object
If frame structure is optimized for weight reduction, then weight decreases, but assembly performance and manufacturing complexity increase
Solution Approach 1:
The frame structure is segmented into modular beam components that can be manufactured separately and assembled systematically. This segmentation enables pre-fabrication of individual beam segments with optimized geometries, reducing overall manufacturing complexity despite the sophisticated weight-optimized design.
Solution Approach 2:
The beam segments are designed with universal connection interfaces and standardized mounting positions that serve multiple functions: structural load-bearing, component mounting, and assembly alignment. This multi-functionality simplifies the manufacturing process by reducing the number of specialized components needed.
Data Source
AI summary
An all-terrain vehicle includes a frame; four wheels; a suspension system; and a prime mover assembly. The frame includes auxiliary main beams which extend upwardly from a mid-height of one of the mid-rear pillars in a front tube section, and then angles from 120 to 170° to a longitudinal portion welded along its length to the upper main beam. The front tube sections each define a triangular shape together with the mid-rear pillars and the upper main beams. The all-terrain vehicle includes a front mounting bracket and two cargo rack structures, a cooling fan cover which supports several components of the cooling system, rear suspension swing arm mount plates formed of sheet metal, a passenger seat that elastically allows backrest lean angle changes, and a dual action brake caliper.