Front Cross Bar Structure for Low-Interference EV Assembly
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Solution Overview
Problem
Conventional front cross bar structures in electric vehicles are costly and inconvenient to assemble, as they require pre-assembly before other components, leading to interference with assembly tools and worker movement, and are often made from expensive aluminum extruded materials.
Innovation Solution
A front vehicle-body structure featuring a cross bar with an open bottom and lateral end section, mounted between side members via brackets with engagement units and guide studs, allowing for assembly after other components are in place, using steel material to reduce cost and weight while maintaining strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the front cross bar is assembled to the front side member before assembling other assembly components, then interference between assembly components and fastening tools is avoided, but worker movement and working posture are inconvenienced
Solution Approach 1:
The invention divides the assembly process into two independent stages: first assembling the cross bar to the side members using self-tapping screws, then assembling other components. The cross bar structure with pre-drilled holes and threaded portions enables this segmented approach, allowing workers to complete fastening operations before other components are installed, eliminating interference while maintaining worker mobility.
Solution Approach 2:
The cross bar is prepared in advance with drilled holes and threaded portions formed before assembly. This preliminary preparation allows the cross bar to be quickly attached to side members at the beginning of the assembly process, establishing a stable foundation that doesn't interfere with subsequent component assembly while enabling workers to maintain comfortable positions throughout the process.
2Strength
If aluminum extruded material with circular or rectangular closed cross-section is used for the front cross bar, then structural strength is achieved, but production cost increases
Solution Approach 1:
The invention changes the cross-sectional geometry parameter from closed circular or rectangular sections to an open U-shape with a bottom wall and two side walls. This parameter change reduces manufacturing complexity and material usage while maintaining sufficient structural strength through the engagement of mounting brackets with the side walls. The open configuration also facilitates easier assembly and reduces production costs compared to closed-section extrusions.
Solution Approach 2:
The cross bar uses a simpler, less expensive open-section design rather than costly closed-section aluminum extrusions. The mounting brackets provide the necessary structural reinforcement, allowing the cross bar itself to be made from more economical materials and manufacturing processes while achieving the required structural performance for supporting assembly components.
3Device complexity
If the cross bar is directly engaged with front side members, then assembly simplicity is achieved, but assembly flexibility is reduced
Solution Approach 1:
The invention introduces mounting brackets as intermediary components between the cross bar and the side members. These brackets engage with the side walls of the cross bar and provide adjustable positioning, allowing the cross bar to be securely attached while maintaining flexibility for accommodating different assembly component positions and configurations. The brackets act as mediators that simplify the direct engagement while enhancing adaptability.
Data Source
AI summary
A front vehicle-body structure may include a pair of front side members each disposed in a vehicle length direction at both sides of a front vehicle-body, a pair of mounting brackets each engaged with a corresponding front side member among the pair of front side members and disposed to protrude from an internal panel of the corresponding front side member in a width direction of the vehicle to face each other, a cross bar having an upper surface, a front surface, and a rear surface, having a cross-section having an open bottom side and an open lateral end portion, and engaged with the mounting bracket in a vehicle height direction thereof, and an engagement unit of engaging the cross bar to the pair of mounting brackets with a predetermined gap between the pair of front side members and the lateral end portion of the cross bar.