Modular Front Cross Member Cooling Integration
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Solution Overview
Problem
Existing vehicle frames for commercial vehicles face challenges in integrating larger cooling modules due to space constraints and require a high number of specially shaped components, leading to increased weight and complexity, making it difficult to adapt to different equipment variants and types of vehicles.
Innovation Solution
A modular welded skeleton front cross member design that integrates at least one cooling module, using standardized structural elements such as pipes, sheet metal, and forged parts, allowing for flexible adaptation to different vehicle models and equipment configurations while minimizing installation space and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid front axle with trailing arms is articulated at points fixed to the frame using a U-shaped cross member composed of multifunctional end shields and a crossbeam, then the front cross member provides structural support and rigidity, but a large number of specially shaped components are required resulting in high overall weight and increased complexity
Solution Approach 1:
The front cross member is divided into modular components: two end shields and a crossbeam that can be assembled separately. This segmentation allows each component to be optimized independently and facilitates easier manufacturing and assembly while reducing the need for heavy monolithic structures.
Solution Approach 2:
The end shields are designed as multifunctional components that serve multiple purposes: structural support, mounting points for trailing arms, and integration with the crossbeam. This multi-functionality reduces the total number of separate components needed, thereby reducing overall weight and complexity while maintaining structural integrity.
2Strength
If specially shaped and adapted components are manufactured using original and forming processes to achieve the required structural integrity, then the front cross member meets structural requirements, but the high degree of customization does not allow optional configuration to other equipment variants or types of commercial vehicle
Solution Approach 1:
By segmenting the front cross member into standardized end shields and a crossbeam, the design allows different combinations and configurations to be assembled for various vehicle types and equipment variants, while each individual component can be manufactured using standardized processes.
Solution Approach 2:
The multifunctional end shields are designed with universal mounting points and standardized interfaces that can accommodate different configurations and vehicle types, enabling the same basic component design to be adapted across multiple applications without requiring completely custom manufacturing for each variant.
3Temperature
If more cooling capacity is required to achieve emission values of newer exhaust gas regulations for water-cooled diesel engines, then larger cooling modules are needed, but larger cooling modules require larger installation space which is not available with conventional front cross member designs
Solution Approach 1:
The cooling module is integrated within the structural framework of the front cross member, with cooling components nested between the end shields and crossbeam. This nesting arrangement allows the cooling system to occupy otherwise unused space within the structural assembly, providing larger cooling capacity without increasing the overall external dimensions.
Solution Approach 2:
The front cross member structure and cooling module are merged into a single integrated assembly. The structural components serve dual purposes: providing mechanical support and housing the cooling system. This combination eliminates the need for separate mounting space for the cooling module, allowing larger cooling capacity within the same installation envelope.
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
The arrangement has two longitudinal bearers (2) connected at several distributed points by transverse bearers. The front regions of both longitudinal bearers are joined by a front transverse bearer (3) joined to the ends of the longitudinal bearers by connecting bodies (4). The front transverse bearer is a modular welded or cast framework with a number of construction elements forming a framelike multifunctional bearer unit for at least one cooling module.