Utility Vehicle Frame Segmented Stamped Assembly
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Solution Overview
Problem
Current utility vehicle frames face challenges in balancing strength, rigidity, manufacturability, and repairability while efficiently absorbing off-road shocks and protecting occupants.
Innovation Solution
A frame system for utility vehicles comprising a split upper and lower frame assembly with stamped frame pieces, joined by coupling members and seals, enhancing structural integrity and manufacturability through modular design and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional frame assemblies are used, then strength and rigidity are maintained, but manufacturability and repairability are reduced
Solution Approach 1:
The frame assembly is divided into multiple stamped frame pieces (first stamped frame piece, second stamped frame piece, third stamped frame piece, fourth stamped frame piece) that are coupled together through joint members. This segmentation allows each piece to be manufactured separately using stamping processes, improving manufacturability while maintaining overall frame strength through the coordinated assembly of multiple components.
2Strength
If frame assembly complexity is increased to improve strength, then strength is improved, but ease of assembly and repair are reduced
Solution Approach 1:
Joint members serve as intermediary components that simplify the assembly process. Each joint member is configured to receive and couple multiple stamped frame pieces together, acting as a mediator that reduces the complexity of direct piece-to-piece connections. This intermediary approach maintains structural integrity while facilitating easier assembly and repair operations.
3Ease of repair
If traditional non-modular frame design is used, then structural integrity is maintained, but repairability is reduced
Solution Approach 1:
The frame is segmented into multiple replaceable stamped frame pieces coupled through joint members. This segmentation enables modular repair approaches where damaged components can be individually replaced without compromising the overall structural integrity of the frame assembly, thereby improving repairability while maintaining stability.
4Strength
If frame assembly uses fewer components, then ease of manufacture is improved, but strength and rigidity are reduced
Solution Approach 1:
Multiple stamped frame pieces are merged through coupling with joint members to create a unified frame assembly with enhanced strength and rigidity. The merging of these components through standardized joint interfaces achieves superior structural performance while managing complexity through systematic design of the coupling mechanisms.
Data Source
AI summary
An upper frame assembly for a vehicle is provided. The upper frame assembly comprises a first generally upstanding frame member comprising a first stamped frame piece coupled to a second stamped frame piece, and a first longitudinally extending frame member at least partially longitudinally aligned from a top view with the first generally upstanding frame member. The first longitudinally extending frame member comprises a third stamped frame piece coupled to a fourth stamped frame piece, and a first joint member defining a first coupling location and a second coupling location. The first joint member comprises a first joint stamped piece and a second joint stamped piece, and the first longitudinally extending frame member is coupled to the first joint member at the first coupling location. Further, the first generally upstanding frame member is coupled to the first joint member at the second coupling location.