Vehicle Crossmember Assembly Double Box Structure
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Solution Overview
Problem
Conventional crossmember assemblies for vehicles face challenges in securing sufficient rigidity and improving assembling characteristics due to interference with the drive portion for active roll control (ARC) and limited space, which complicates the mounting of reinforcement plates and lower arm mounting portions.
Innovation Solution
A crossmember assembly design featuring an upper panel and lower panels assembled in a double box shape, with the lower panel covering the ARC drive portion without interference, and incorporating front/rear side lower arm mounting panels separated in the front/rear direction to enhance forming and assembling characteristics, including the use of extruded lower brackets for stabilizer bar mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the lower panel is integrally formed with the lower arm mounting portion, then the structure is simplified, but the rigidity cannot be secured and forming/assembling characteristics are deteriorated
Solution Approach 1:
The lower panel is divided into multiple sections: the main lower panel and separate front/rear side lower arm mounting panels. This segmentation allows each part to be optimized independently - the main panel maintains structural integrity while the separate mounting panels provide enhanced rigidity and improved forming/assembling characteristics at critical mounting locations.
2Strength
If reinforcement plate is mounted on the lower panel, then the rigidity of lower panel is reinforced, but the space is insufficient and interfering with drive portion for ARC
Solution Approach 1:
The reinforcement function is achieved by transitioning from a planar reinforcement plate mounted on the lower panel surface to a three-dimensional lower arm mounting panel structure that extends vertically and integrates with the upper panel, creating a double box structure that provides rigidity without occupying horizontal space needed for the ARC drive portion.
Solution Approach 2:
The lower arm mounting panel is merged with the upper panel to form an integrated double box structure. This combination provides reinforcement and rigidity through the boxed configuration itself, eliminating the need for separate reinforcement plates that would interfere with the ARC drive portion assembly.
3Ease of operation
If the lower panel covers the drive portion for ARC, then the assembling characteristic is improved, but the space for mounting reinforcement plate is reduced
Solution Approach 1:
The solution moves the reinforcement function from the horizontal plane (where it would conflict with ARC drive portion) to the vertical dimension by creating a double box structure through the lower arm mounting panel that connects to the upper panel, providing reinforcement without reducing horizontal mounting space.
Data Source
AI summary
A crossmember assembly for a vehicle may include an upper panel; a pair of lower panels assembled at a lower side of both end portions of the upper panel to form a first box, a center lower panel, a middle portion of which is assembled to a lower middle portion of the upper panel, and a front side lower arm mounting panel and a rear side lower arm mounting panel that are disposed at a lower front side and a lower rear side of the crossmember assembly, respectively, and mounted to the both end portions of the upper panel to house a lower arm.