Integrated Cast Vehicle Body Structure With Runners and Ribs
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Solution Overview
Problem
Current vehicle body manufacturing methods, such as monocoque welding and aluminum space frames, are inefficient for small-volume production due to high mold costs, complex manufacturing processes, and increased production cycle times, while casting methods face challenges in minimizing parts and ensuring strength.
Innovation Solution
A casting vehicle body structure that integrates a fender apron upper member, shock absorber housing, and front side member with protruding runners and ribs, facilitating the flow of molten metal and reducing the number of parts required, while enhancing structural strength and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If monocoque welding method is used to produce vehicle body, then mass production efficiency is improved, but the number of parts and assembly complexity increases significantly
Solution Approach 1:
The patent combines multiple separate structural components (front apron upper member, shock absorber housing, front side member) into a single integrated casting part. This merging eliminates the need for welding and assembly of 70+ individual steel panels, reducing part count while maintaining structural integrity and enabling simplified production processes suitable for small-volume manufacturing.
2Adaptability or versatility
If aluminum space frame structure is used for small-volume production, then adaptability is improved, but part layout complexity and manufacturing cost increase
Solution Approach 1:
The integrated casting structure consolidates multiple space frame components into one piece, eliminating complex part layouts and connections. This approach provides the adaptability needed for small-volume production while avoiding the complexity of assembling multiple aluminum space frame parts.
3Manufacturing precision
If high vacuum die-casting parts are used, then manufacturing precision is improved, but investment cost increases
Solution Approach 1:
The patent applies local quality enhancement through strategically placed runners and ribs within the casting structure. These features are localized to specific areas where strength and precision are needed, rather than requiring high vacuum die-casting throughout the entire part. This reduces investment cost while maintaining manufacturing precision in critical areas.
4Device complexity
If casting method is used to minimize parts, then device complexity is reduced, but structural strength may be compromised
Solution Approach 1:
The patent incorporates runners and ribs as preliminary structural features during the casting process itself. These features are built into the part during manufacturing, providing inherent strength enhancement before the part is put into service. This preliminary action ensures structural integrity is maintained while keeping the part count low.
Solution Approach 2:
The runners and ribs are strategically positioned in areas requiring enhanced strength, providing local quality improvement. This allows the integrated casting to achieve necessary structural strength without requiring additional reinforcing parts or complex assemblies.
Data Source
AI summary
An embodiment casting vehicle body structure includes a fender apron upper member, a shock absorber housing disposed under the fender apron upper member, a front side member disposed under the shock absorber housing, a side member runner protruding from an inner surface of the front side member, and a side member rib protruding from the side member runner.