Split Load-Bearing Beam Frame Assembly for Vehicle Connection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing modular frame assemblies for vehicles, particularly heavy-duty truck trailers, face challenges in providing sufficient strength and stiffness at connection areas while maintaining cost-efficiency and reducing weight, which is crucial for reducing energy consumption and environmental impact.
Innovation Solution
A load-bearing frame assembly with a first and second frame mechanically coupled at a connecting area, where the load-bearing beam of the first frame is split into upper and lower portions with a reinforcement plate, forming a space that diverges in height to create a geometrically stable and strong connection, optionally overlapping for enhanced strength and stiffness, and using a z-formed beam for improved access and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If modular frame assemblies are used to improve manufacturing efficiency and reduce cost, then productivity and ease of manufacture are improved, but the strength and stiffness at connection areas deteriorate
Solution Approach 1:
The frame assembly is divided into modular sub-frames that can be manufactured separately and assembled together, improving productivity while maintaining connection strength through specialized connection designs
Solution Approach 2:
The connection design embeds reinforcement elements within the connection area, with reinforcement plates positioned between sub-frames and integrated with the beam structures, creating a nested configuration that maximizes strength within the modular assembly
2Reliability
If traditional connection methods are used to ensure sufficient strength at connection areas, then reliability is improved, but weight increases
Solution Approach 1:
The reinforcement is concentrated specifically at the connection areas where it is most needed, rather than uniformly throughout the entire frame structure, optimizing the strength-to-weight ratio by placing material only where structurally necessary
Solution Approach 2:
The connection assembly combines different structural elements (beams, reinforcement plates, and connecting components) into a composite structure that achieves high strength through the synergistic arrangement of parts rather than relying on a single heavy component
3Stability of the object's composition
If the load-bearing beam is split into upper and lower portions to create a space for connection, then the connection interface is improved and geometric stability is enhanced, but device complexity increases
Solution Approach 1:
The load-bearing beam is segmented into upper and lower portions that diverge to create connection space, allowing the reinforcement plate to be positioned between them and mechanically couple to both sub-frames, enhancing geometric stability through this segmented configuration
Solution Approach 2:
The beam portions diverge in the height extension (vertical dimension) to create space for the connection interface, utilizing the vertical dimension to accommodate the reinforcement plate and connection components without increasing the longitudinal footprint of the assembly
Data Source
Figure 1
Figure 2a~2b
Figure 3a
AI summary
The present disclosure relates to a load-bearing frame assembly (1) for a vehicle, comprising, a first (10) and a second (20) frame configured to receive and support material to be transported, the first and the second frame being successively arranged in a longitudinal extension (L) of the frame assembly and mechanically coupled to each other at a connecting area (A), the first frame (10) comprising at least one longitudinally extending load-bearing beam (100) having an upper (101) and a lower (102) flange section interconnected by a web section (103), a portion of the at least one load-bearing beam (100) facing the second frame (20) being split in the longitudinal extension along the web section (103), thereby forming an upper and a lower beam portion (110, 120) having respective upper and lower split web sections (111, 121), the upper and lower beam portions (110, 120) diverging in a height extension (h) of the frame assembly towards the second frame (20) such that they form a space (S) between each other, the upper beam portion (110), the lower beam portion (120) and the second frame (20) being mechanically coupled by a reinforcement plate (30).