Off-Road Vehicle Frame With Rising Longitudinal Beams
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Solution Overview
Problem
Off-road vehicles like UVs and ATVs face challenges in frame design that fail to adequately support the substantial forces and allow sufficient suspension travel without interference, particularly due to the off-road nature and jarring conditions, which existing frame structures do not effectively address.
Innovation Solution
A frame design featuring main beams with closer longitudinal spacing and additional swing arm mounting beams that rise to accommodate rear suspension travel, allowing for stronger support of thrust and drag forces while enabling greater suspension movement without interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If main beams are spaced widely apart to reduce frame complexity and manufacturing cost, then ease of manufacture is improved, but structural strength deteriorates due to insufficient support for substantial off-road forces
Solution Approach 1:
The frame is divided into multiple longitudinal members including main beams and additional support beams (such as swing arm mounting beams). This segmentation distributes the structural load across multiple elements rather than relying on widely spaced main beams alone, thereby maintaining structural strength while keeping individual beam spacing manageable for manufacturing purposes.
Solution Approach 2:
Different regions of the frame have different beam spacing configurations. Main beams are spaced wider apart in non-critical areas to reduce complexity, while additional support beams are placed closer together in high-stress areas (such as near the rear suspension and swing arm mounting locations) to provide localized strength where off-road forces are most substantial.
2Ease of manufacture
If frame structure is simplified with fewer beams and plates, then ease of manufacture is improved, but ability to support substantial off-road forces deteriorates
Solution Approach 1:
The frame structure is segmented into main beams for overall structural support and additional specialized beams (such as swing arm mounting beams) for specific high-force areas. This allows the frame to handle substantial off-road forces through distributed support while maintaining relative manufacturing simplicity by using standardized beam and plate components that can be efficiently produced and assembled.
Solution Approach 2:
The longitudinal beams and cross plates are designed to serve multiple functions. For example, the swing arm mounting beams not only provide structural support but also serve as mounting points for suspension components. This multi-functionality reduces the need for separate dedicated parts, thereby simplifying manufacture while maintaining force support capacity.
3Ease of manufacture
If longitudinal beams extend horizontally within the base plane, then ease of manufacture is improved, but suspension travel is interfered with due to obstruction of rear suspension movement
Solution Approach 1:
The longitudinal beams are designed with dynamic geometry rather than simple horizontal extension. The beams curve upward from the base plane toward the rear of the vehicle, creating a three-dimensional configuration that adapts to the space requirements of the suspension system. This dynamic shaping allows sufficient clearance for suspension travel while maintaining structural integrity and reasonable manufacturability through standard tube bending processes.
Solution Approach 2:
The longitudinal beams transition from a two-dimensional horizontal layout to a three-dimensional configuration by curving upward. This dimensional change allows the beams to clear the rear suspension components that move vertically and horizontally, providing sufficient suspension travel freedom while still connecting to the base plane at the front and achieving structural support functions.
4Strength
If additional swing arm mounting beams are added to support rear suspension forces, then structural strength is improved, but device complexity increases
Solution Approach 1:
The swing arm mounting beams are designed as multi-functional elements that provide both structural support for thrust and drag forces and serve as mounting points for suspension components. By combining these functions into single integrated beams rather than separate support structures and mounting brackets, the overall device complexity is minimized while maintaining the necessary structural strength.
Solution Approach 2:
The swing arm mounting beams are merged with the overall longitudinal beam structure rather than being separate independent components. This merging reduces the total number of parts and connections required, thereby reducing construction complexity while still providing the necessary strength to support rear suspension forces through the integrated beam structure.
Data Source
AI summary
A frame for an off road vehicle includes main beams establishing a base plane. Mounting beams, which can be used to support forces from the swing arm of a rear suspension, are spaced outside the main beams and within the base plane, running longitudinally in line with the swing arms of the rear suspension. Right and left longitudinal beams start within the base plane, but rise to their trailing ends so as to not interfere with the suspension travel of the swing arms as they extend back inward over the swing arms. Front and rear support columns can further attach into, secure and support the mounting beams and the longitudinal beams. All of the beams and columns can be formed by cutting cylindrical tubing to length and then curving the cylindrical tubing, each piece within a single plane.