Vehicle Body Frame Connector With 3D Beam Positioning
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Solution Overview
Problem
Existing vehicle body frame joints suffer from insufficient fatigue durability, connection stiffness, and complex assembly processes due to inadequate joint designs that often connect only two vertical surfaces of transverse and longitudinal beams, leading to manufacturing and assembly errors that decrease efficiency.
Innovation Solution
A body frame joint comprising a first and second sub-joint with transverse and longitudinal beam connection grooves, allowing for multi-directional positioning of beams, enhancing fatigue endurance and connection stiffness, while a separated structure simplifies assembly requirements and improves efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a joint connects only two vertical surfaces of transverse and longitudinal beams, then the joint structure is simple, but the fatigue durability and connection stiffness are insufficient
Solution Approach 1:
The joint is divided into first and second sub-joints that are disposed separately and engage with each other. The first sub-joint connects to the transverse beam while the second sub-joint connects to the longitudinal beam, creating a segmented connection system that improves fatigue durability through multi-directional positioning
2Device complexity
If a joint connects only two vertical surfaces of transverse and longitudinal beams, then the joint structure is simple, but the connection stiffness is insufficient and deformation is large
Solution Approach 1:
The connection is extended from two-dimensional (two vertical surfaces) to three-dimensional by adding multi-directional positioning capabilities. The first and second sub-joints engage to provide positioning in multiple directions, significantly improving connection stiffness and reducing deformation
3Strength
If a joint connects two side surfaces of transverse and longitudinal beams in addition to vertical surfaces, then the connection strength is improved, but the assembly difficulty increases
Solution Approach 1:
The joint is segmented into first and second sub-joints that can be assembled separately and then engaged. This segmentation allows for easier assembly compared to connecting all surfaces simultaneously, while still achieving improved connection strength through the engaged sub-joint structure
4Manufacturing precision
If high assembly accuracy is required to accommodate manufacturing and assembly errors, then the connection precision is improved, but the assembly efficiency decreases
Solution Approach 1:
The first and second sub-joints are designed with pre-defined engagement features that automatically position the transverse and longitudinal beams in multiple directions. This preliminary positioning action compensates for manufacturing and assembly errors without requiring high assembly accuracy, thereby improving assembly efficiency
Data Source
AI summary
A body frame joint and a vehicle having the same are provided. The body frame joint includes: a first sub-joint; and a second sub-joint. The first sub-joint and the second sub-joint are adapted to be mounted to a body frame. A transverse beam connection groove and a longitudinal beam connection groove are defined by engaging the first sub-joint and the second sub-joint. The transverse beam connection groove is adapted to accommodate a transverse beam of the body frame, and the longitudinal beam connection groove is adapted to accommodate a longitudinal beam of the body frame.