Vehicle Support Structure with Nested Rail and Cross-Member Pocket
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle support structures, particularly in pickup trucks, face challenges in optimizing the positioning and interlocking of cross-members and rails, which affects the cargo bed's height and size, as well as accessibility for accessory attachments.
Innovation Solution
A vehicle support structure design where the rail is nested within a pocket of the cross-member, allowing for a lower cargo bed height and enhanced accessibility, with a hat-shaped cross-section configuration and an opening for accessory attachment, enabling direct connection of accessories and supporting D-pillars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the rail is nested within the cross-member pocket, then the cargo bed height is reduced and accessibility is improved, but the structural complexity of the support structure increases
Solution Approach 1:
The rail is nested within a pocket of the cross-member, with the longitudinal end portion of the rail disposed within the interior of the cross-member. This nesting arrangement reduces the step-in height to the cargo bed and improves accessibility while maintaining structural integrity through the interlocking configuration of the rail and cross-member.
2Volume of moving object
If the rail is nested within the cross-member pocket, then the cargo bed size is increased, but the manufacturing precision requirements increase
Solution Approach 1:
The rail is nested within a pocket of the cross-member, with the longitudinal end portion of the rail disposed within the interior of the cross-member. This nesting arrangement increases cargo bed volume while the pocket configuration provides built-in positioning guidance that helps manage manufacturing precision requirements.
Solution Approach 2:
The support structure is divided into distinct components (rails and cross-members) with specific geometric features (pockets, openings) that segment the assembly process and allow for modular manufacturing, reducing the overall precision requirements compared to a monolithic structure.
3Strength
If the cross-member is positioned to support the D-pillar outboard of the rail, then the structural strength is improved, but the device complexity increases
Solution Approach 1:
The support structure is segmented into rails and cross-members that can be independently positioned and assembled. The cross-member is positioned to support the D-pillar outboard of the rail, creating a segmented configuration that improves structural strength while allowing for modular assembly and reduced overall complexity.
Data Source
AI summary
A vehicle support structure according to an exemplary aspect of the present disclosure includes, among other things, a cross-member of a vehicle support structure. The cross-member extends longitudinally along a cross-member axis. The frame assembly further includes a rail of the vehicle support structure. The rail extends longitudinally along a rail axis that is transverse to the cross-member axis. The rail extends into a pocket of the cross-member such that a portion of the rail is nested within the cross-member.