Axleless Wheel-Beam Vehicle Frame for Lightweight Design
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Solution Overview
Problem
Existing motor vehicle frames face challenges such as high weight, elevated center of gravity, restricted space, complex design, and high production costs, which hinder the goals of lightweight, electrification, and intelligentization, particularly in the context of axle-based structures.
Innovation Solution
A wheel beam type axleless vehicle frame is designed, where the axle's locating and bearing functions are replaced by a floor and sides, allowing direct suspension connection to wheels, reducing vehicle height, expanding space, and enabling independent suspension systems, with a modular structure comprising five sections that can be adjusted and combined for various models.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional axles and crossbeam structures are used, then the vehicle frame can support loads and maintain structural integrity, but the vehicle weight increases and the center of gravity is elevated
Solution Approach 1:
The patent removes the traditional axle component from the vehicle frame structure. The axle's locating and bearing functions are transferred to the floor and side structures, eliminating the need for separate axle assemblies and reducing overall vehicle weight while maintaining structural integrity
Solution Approach 2:
The patent integrates the functions previously performed by separate axles into the floor and side beam structures. The floor and sides directly connect to and support the suspensions, merging the axle's bearing and locating functions with the frame structure itself, thereby reducing component count and weight
2Strength
If traditional axles and crossbeam structures are used, then the vehicle frame can support loads, but the center of gravity is elevated and interior space is reduced
Solution Approach 1:
By removing the traditional axle component, the patent eliminates the structural elements that elevate the center of gravity. The floor and side structures directly support the suspensions, lowering the overall vehicle height and increasing interior space while maintaining load support capability
Solution Approach 2:
The patent transitions from a three-dimensional axle assembly to a two-dimensional floor and side structure configuration. This dimensional change allows the suspension connection points to be positioned lower, reducing vehicle height and maximizing interior volume
3Productivity
If platform frame with integrated shaping is used, then mass production is facilitated, but high technical requirements and complex production processes are required
Solution Approach 1:
The patent divides the vehicle frame into modular sections including front and rear sections with wheel carriers, intermediate coupling sections, and hanging racks. These standardized modules can be produced separately and assembled, facilitating mass production while reducing the technical complexity of each individual component
4Strength
If space type monocoque structure is used, then vehicle frame strength is improved, but the design becomes complicated with numerous parts and weld joints
Solution Approach 1:
The patent employs a modular segmented design with standardized wheel carriers, coupling racks, and hanging racks that can be independently designed and manufactured. This segmentation simplifies the overall design complexity while maintaining frame strength through proper modular connections
Solution Approach 2:
The patent creates universal standardized modules such as wheel carriers and coupling racks that can be applied across different vehicle models. These multi-functional components reduce design complexity by using standardized connection interfaces and structural elements
Data Source
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AI summary
The present application discloses a wheel beam type axleless vehicle frame that comprises five sections in sequence from front to back, including a front hanging rack, a front wheel carrier, an intermediate coupling rack, a rear wheel carrier, and a rear hanging rack. Every two adjacent sections amongst the five sections are manufactured and connected in a unified and standardized integrated mode; a modular combination structure is used; and the five sections, which are independent respectively, may be assembled and adjusted according to requirements, and have sufficient strength and stiffness as well as completely independent interchangeability. According to the present application, laterally-loaded connection of the vehicle frame, wheel alignment, and integration of suspensions and elastic elements as well as resistance points on the vehicle frame are achieved. The vehicle frame is capable of reasonably bearing all the loads with axles being removed. The vehicle frame can be matched with all the other elastic elements than leaf springs in various suspensions; and the height of the floor of a motor vehicle can be reduced significantly, such that the utilization of the interior space of a vehicle is enhanced to a large extent effectively and the comfort is enhanced. The vehicle frame has the advantages that match with the needs of an electric vehicle, and thus may be used as the optimum configuration frame for the electric vehicle; and the vehicle frame may be improved according to requirements to be applicable to various fuel and hybrid electric passenger vehicles and commercial vehicles.