Auxiliary Frame Support for Vehicle Gas Tanks and Battery Space
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Solution Overview
Problem
Existing light duty vehicle structures face challenges in achieving a balance between structural resistance, reliability, and cost-effectiveness, particularly in supporting auxiliary units like gaseous fuel tanks or electric batteries, where the absence of cross-members requires alternative structural solutions.
Innovation Solution
The introduction of an auxiliary frame with connection plates projecting from flanges that rigidly connect to the vehicle's longitudinal beams, forming a quadrangular configuration with a cross-member that secures auxiliary units and acts as a structural element to counteract deformations, replacing the need for cross-members and simplifying assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If cross-members are omitted to leave space for auxiliary units, then the space for auxiliary units is increased, but the structural resistance and reliability of the vehicle frame deteriorate
Solution Approach 1:
The auxiliary frame is merged with the vehicle frame structure by rigidly connecting connection plates to the longitudinal beams. This integration allows the auxiliary frame to fulfill both the function of supporting auxiliary units and providing structural reinforcement, replacing the need for separate cross-members in those areas.
Solution Approach 2:
The auxiliary frame serves multiple functions: it supports auxiliary units (gas tanks or electric batteries), provides structural reinforcement equivalent to cross-members, and contributes to the overall rigidity of the vehicle frame. This multi-functionality resolves the contradiction by making the auxiliary frame structure serve both spatial and structural purposes.
2Reliability
If an auxiliary frame with rigid connection plates is introduced to replace cross-members, then the structural reliability is improved, but the device complexity increases
Solution Approach 1:
The auxiliary frame structure serves dual purposes as both a support framework for auxiliary units and a structural reinforcement element replacing cross-members. This multi-functionality reduces the need for separate components, thereby improving reliability without proportionally increasing complexity.
Solution Approach 2:
The auxiliary frame is divided into modular components including longitudinal arms, transverse arms, and connection plates with flanges. This segmentation allows for standardized manufacturing and assembly, reducing construction complexity while maintaining structural reliability through rigid connections.
3Strength
If connection plates with flanges and abutment elements are used to rigidly connect the auxiliary frame, then the structural resistance against deformation is improved, but the manufacturing complexity increases
Solution Approach 1:
The connection structure is segmented into distinct functional elements: flanges that project from connection plates, and abutment elements that contact the lower walls of longitudinal beams. This segmentation allows each component to be manufactured separately using standard fabrication processes, then assembled through rigid connections, balancing manufacturing ease with structural strength.
Solution Approach 2:
The connection plates act as intermediary elements between the auxiliary frame and the vehicle frame's longitudinal beams. These plates with their flanges and abutment elements provide a standardized interface that simplifies the connection process while ensuring rigid structural attachment, thereby improving resistance against deformation without significantly complicating manufacturing.
4Strength
If the auxiliary frame is designed with a quadrangular configuration and cross-member, then the structural function is improved, but the production cost increases
Solution Approach 1:
The auxiliary frame with its quadrangular configuration and cross-member is merged with the vehicle frame structure, replacing the need for separate cross-members. This consolidation reduces the total number of components required, thereby lowering production costs while maintaining or improving structural function.
Solution Approach 2:
The auxiliary frame structure serves multiple structural functions simultaneously: it provides the quadrangular configuration for rigidity, includes cross-members for additional reinforcement, and replaces traditional cross-members entirely in certain areas. This multi-functionality reduces the overall component count and production complexity, offsetting the increased design complexity with manufacturing efficiencies.
Data Source
AI summary
A light duty vehicle includes a vehicle frame, including a pair of vehicle longitudinal beams connected to each other by a plurality of cross-members and a cabin frame, having a pair of cabin longitudinal beams rigidly connected to front ends of the vehicle longitudinal beams. A supporting structure for auxiliary units, such as gaseous fuel tanks or electric batteries, which is carried by the vehicle frame, and includes an auxiliary frame extending between the vehicle longitudinal beams and having connection plates arranged in vertical planes parallel to a longitudinal direction of the vehicle frame and which are in contact with mutually facing inner lateral walls of the vehicle longitudinal beams and are rigidly connected to these longitudinal beams. The auxiliary frame fulfills a structural function equivalent to the structural function of one or more cross-members at an area of the vehicle frame where the cross-members are omitted.