Split Cross-Member Assembly for Obstructed Vehicle Chassis Mounting
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Solution Overview
Problem
The assembly of transverse cross-members in vehicle chassis is complicated, especially when other components are already installed, due to obstructed access, and there is a need for a design that accommodates frame width tolerance and liner presence.
Innovation Solution
A transverse cross-member beam composed of two beam halves with mating surfaces and abutment portions that allow for adjustable assembly and temporary holding, along with mounting brackets that facilitate stable connection to longitudinal frame members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a transverse cross-member is assembled into the chassis after other components have been installed, then the chassis assembly can be completed, but the access to the cross-member location is partially obstructed by previously mounted vehicle components
Solution Approach 1:
The transverse cross-member is divided into two separate beam halves that can be independently positioned and attached to the longitudinal frame members. This segmentation allows the beam halves to be installed in the gap between previously mounted components, overcoming the access obstruction problem while still forming a complete cross-member structure.
Solution Approach 2:
Mounting brackets are introduced as intermediary elements between the beam halves and the longitudinal frame members. These brackets provide accessible mounting points that can be reached from the exterior, facilitating the attachment of beam halves without requiring direct access to the cross-member location behind other components.
2Reliability
If the cross-member assembly requires precise alignment and fixation, then the structural integrity is ensured, but the assembly complexity increases
Solution Approach 1:
By dividing the cross-member into two beam halves with corresponding mating surfaces, the assembly process becomes more manageable. Each beam half can be independently aligned and attached, reducing the overall alignment complexity while ensuring structural integrity through the precise mating of the halves.
Solution Approach 2:
The beam halves incorporate self-aligning features such as mating surfaces and abutment portions that automatically guide proper alignment during assembly. This self-alignment capability reduces the need for complex external alignment procedures while maintaining precise positioning and structural integrity.
3Adaptability or versatility
If the beam halves are designed with multiple relative positions for mating surfaces, then the adaptability to frame width tolerances and liner presence is improved, but the device complexity increases
Solution Approach 1:
The beam halves are designed with mating surfaces that can accommodate multiple relative positions, allowing the same beam half design to work with different frame widths and liner configurations. This multi-position capability provides universality across different vehicle models and configurations without requiring multiple specialized beam designs.
Solution Approach 2:
The design incorporates adjustable parameters in the mating surface geometry, allowing the relative positioning of beam halves to be modified to accommodate frame width tolerances and liner presence. This parameter flexibility enables adaptation to various conditions while maintaining a consistent basic design, balancing versatility with complexity.
Data Source
AI summary
A transverse cross-member beam for a vehicle chassis, comprising a first and a second beam half, each beam half having an external extremity for connection a longitudinal frame member, and each beam half having an internal extremity; wherein the internal extremity of each beam half has a mating surface configured for mating to the mating surface of the other beam half at one of at least two distinct relative positions separated along a horizontal transverse axis, with fixation features; and wherein the internal extremity of each beam half has a first abutment portion configured for abutment against a second abutment portion of the other beam half, configured to block relative movement of each beam half internal extremity relative to the external extremity of the beam half.