Cap Bracket Sub-Frame Mounting for Flat Floor Load Distribution
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Solution Overview
Problem
The existing sub-frame mounting structures in vehicles, particularly in small commercial MPVs, face challenges in maintaining a flat floor structure while ensuring strength and durability, as increasing the height of the rear mounting portion of the front sub-frame leads to weakened X-axial and Y-axial load resistance and increased Z-axial chassis input loads, causing durability issues and misalignment with surrounding components.
Innovation Solution
A 'cap' type sub-frame mounting structure is implemented, featuring a transverse vehicle body structure with fender apron side members, side extensions, a tunnel member, and a cap type bracket that connects and reinforces the components, ensuring a flat floor structure and improved load distribution, thereby enhancing the vehicle's strength and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the height of the rear mounting portion of the front sub-frame is increased to implement a flat floor structure, then the flat floor structure is achieved, but the mounting portion becomes weak against X-axial and Y-axial loads and the Z-axial chassis input load increases
Solution Approach 1:
The front side member is divided into multiple components: the main front side member, rear mounting portions extending rearward, and side extensions extending laterally. This segmentation allows each component to be optimized for its specific function while collectively achieving the flat floor structure with adequate strength distribution.
Solution Approach 2:
The invention transitions from a vertical height increase approach to a horizontal extension approach by adding side extensions that extend laterally from the rear mounting portions. This dimensional change allows the flat floor structure to be achieved without compromising the mounting portion's load-bearing capacity in the vertical direction.
2Shape
If the height of the rear mounting portion of the front sub-frame is increased, then the flat floor structure is achieved, but the phases of the surrounding portion and the cross member do not coincide
Solution Approach 1:
Side extensions serve as intermediary components that connect the rear mounting portions to the cross member. These extensions provide a transition zone that facilitates proper phase alignment between the surrounding portions and the cross member, enabling precise positioning and coherent integration of all components.
3Device complexity
If a traditional sub-frame mounting structure is used, then the structure is simple, but the durability deteriorates due to increased height and load concentration
Solution Approach 1:
The sub-frame mounting structure is segmented into the front side member, rear mounting portions, and side extensions. This segmentation distributes the chassis input loads across multiple components rather than concentrating them at a single elevated mounting point, thereby improving durability while maintaining reasonable structural simplicity.
Solution Approach 2:
The mounting structure functions as a composite system where the front side member, rear mounting portions, and side extensions work together as an integrated load-bearing assembly. This composite approach enhances overall durability by leveraging the combined strength of multiple components configured in a geometric arrangement that optimizes load distribution.
Data Source
AI summary
A sub-frame mounting combination structure of a vehicle body may include a fender apron side member mounted at the rear end portion of a front side member in the longitudinal direction of the vehicle body, a first side extension disposed in the transverse direction of the vehicle body and connected to the inside of the fender apron side member, a second side extension disposed in the transverse direction and connected to the outside of the fender apron side member, a tunnel member disposed in the transverse direction connecting the first side extensions at both sides at the center portion of the vehicle body to each other, and having the same phase as the first side extension, and a cap type bracket disposed to cover the fender apron side member at a portion where the fender apron side member and the first and second side extensions are connected.