CN115257931A - Integrated cross-shaped inner high-pressure forming energy absorption box structure of auxiliary frame of electric vehicle - Google Patents
Integrated cross-shaped inner high-pressure forming energy absorption box structure of auxiliary frame of electric vehicle Download PDFInfo
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- 238000010521 absorption reaction Methods 0.000 title claims abstract description 125
- 239000000463 material Substances 0.000 claims description 20
- 238000003466 welding Methods 0.000 description 27
- 238000004519 manufacturing process Methods 0.000 description 10
- 238000004080 punching Methods 0.000 description 8
- 238000000034 method Methods 0.000 description 7
- 229910000831 Steel Inorganic materials 0.000 description 6
- 230000005540 biological transmission Effects 0.000 description 6
- 239000010959 steel Substances 0.000 description 6
- 238000005520 cutting process Methods 0.000 description 5
- 229910000838 Al alloy Inorganic materials 0.000 description 4
- 238000003698 laser cutting Methods 0.000 description 4
- 230000001965 increasing effect Effects 0.000 description 3
- 238000012423 maintenance Methods 0.000 description 3
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- 239000003638 chemical reducing agent Substances 0.000 description 2
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D21/00—Understructures, i.e. chassis frame on which a vehicle body may be mounted
- B62D21/15—Understructures, i.e. chassis frame on which a vehicle body may be mounted having impact absorbing means, e.g. a frame designed to permanently or temporarily change shape or dimension upon impact with another body
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Abstract
The invention belongs to the technical field of chassis parts of passenger cars, and particularly relates to an integrated cross-shaped inner high-pressure forming energy absorption box structure of an electric car subframe; the energy absorption box comprises a cross-shaped inner high-pressure forming energy absorption box and an inner high-pressure forming energy absorption box cover plate; the cross-shaped inner high-pressure forming energy absorption box is an integrated piece and has a cross-shaped closed cross-section structure; the upper end face and the lower end face of the energy absorption box main body are respectively provided with a first boss and a second boss, and the left end face and the right end face of the energy absorption box main body are respectively provided with a third boss and a fourth boss; the joint of adjacent bosses on the energy-absorbing box main body is provided with 12 fillets in total, so that 12 main energy-absorbing force-transmitting paths are formed; the invention can realize high collision energy absorption and high collision deformation stability of parts and has the advantages of low cost and light weight.
Description
Technical Field
The invention belongs to the technical field of chassis parts of passenger cars, and particularly relates to an integrated cross-shaped inner high-pressure forming energy absorption box structure of an electric car subframe.
Background
The automobile energy absorption box is used as an important energy absorption device in an automobile passive safety system and is usually arranged between a front bumper anti-collision beam and a front longitudinal beam of an automobile body; the whole electric vehicle has larger weight compared with the traditional vehicle, more and more electric vehicles require the front auxiliary frame to participate in collision, and the energy absorption boxes are simultaneously arranged on the cross beams of the front auxiliary frame, so that the collision safety is further improved; the energy absorption box exists as a passive safety protection system, and the energy absorption box effectively absorbs collision energy when a vehicle collides, so that the safety of passengers in the vehicle is effectively protected, and the damage of the impact force to a power assembly in a front engine room and a vehicle body is reduced as much as possible.
In conclusion, the energy absorption box not only improves the passive safety of the automobile, but also reduces the maintenance cost caused by collision. Therefore, the energy absorption box is generally required to have the characteristics of high energy absorption, high deformation stability during high-pressure collapse, light weight and low cost; however, the conventional crash boxes have the following problems:
1. the aluminum alloy energy absorption box has the advantages that the light weight effect is improved, but the cost of the aluminum alloy material is higher than that of the steel material, and in addition, the energy absorption of the aluminum alloy energy absorption box is lower due to the characteristic relation of the elastic modulus of the aluminum alloy material and the steel material;
2. usually, the steel energy-absorbing box has a square section, and four main energy-absorbing and force-transmitting paths are arranged on the steel energy-absorbing box, and are respectively arranged at four corners of the steel energy-absorbing box, as shown in L1'-L4' in fig. 4, the aspect ratio of the square section is usually set to 1:1; in order to increase the energy absorption, the collision energy absorption is generally improved by increasing the material thickness and the length or the section perimeter of the energy absorption box, but the problems of heavy weight and high cost exist;
3. generally, the steel energy absorption box adopts a stamping and welding structure, a buckling and welding scrap edge 14 (double material thickness and welding heat influence) generates an over-hard area, and due to the manufacturing process, the crushing shape is irregular and the deformation consistency is poor during collision, so that the collision deformation stability of the whole vehicle is influenced.
Disclosure of Invention
In order to overcome the problems, the invention provides an integrated cross-shaped inner high-pressure forming energy absorption box structure of an electric vehicle subframe, which can realize high collision energy absorption performance and high collision deformation stability of parts and has the advantages of low cost and light weight.
An integrated cross-shaped inner high-pressure forming energy absorption box structure of an electric vehicle subframe comprises a cross-shaped inner high-pressure forming energy absorption box 1 and an inner high-pressure forming energy absorption box cover plate 2, wherein the cross-shaped inner high-pressure forming energy absorption box 1 is an integrated piece and is of a cross-shaped closed cross section structure, a first boss 4 and a second boss 5 are respectively arranged on the upper end surface and the lower end surface of the cross-shaped inner high-pressure forming energy absorption box 1, and a third boss 6 and a fourth boss 7 are respectively arranged on the left end surface and the right end surface of the cross-shaped inner high-pressure forming energy absorption box 1; the two ends of the protruding parts of the first boss 4, the second boss 5, the third boss 6 and the fourth boss 7 are respectively provided with a round angle, and the joint of every two adjacent bosses is also provided with a round angle, so that 12 round angles in total are arranged between L1 and L12, and 12 main energy absorption and force transmission paths are formed.
The fillet radii of the L1-L12 are all 1.5 times of the thickness of the material.
The ratio of the transverse width to the longitudinal height of the cross-shaped internal high-pressure forming energy absorption box 1 is 1:1.2.
the cross-shaped inner high-pressure forming energy absorption box 1 is provided with three first concave ribs 8 on the upper end surface of the first boss 4 and the lower end surface of the second boss 5 respectively; three convex ribs 10 are respectively arranged on the left end surface of the third boss 6 and the right end surface of the fourth boss 7; six second concave ribs 9 are respectively arranged on the upper end surface of the third boss 6 and the lower end surface of the fourth boss 7.
The depth of the first concave rib 8 and the second concave rib 9 is set to be 1.25 times of the material thickness, and the height of the convex rib 10 is the same as the depth of the first concave rib 8 and the second concave rib 9.
The maximum perimeter change rate of the cross-shaped inner high-pressure forming energy absorption box 1 along the section of the central axis is about 8%.
The invention has the beneficial effects that:
1. the cross-shaped inner high-pressure forming energy absorption box is of a cross-shaped closed cross-section structure, and 4-surface bosses are arranged on the upper end face, the lower end face, the left end face and the right end face of the energy absorption box body in total; the intersection of the plane and the vertical plane of each boss is provided with a fillet, so that 12 main energy absorption and force transmission paths are formed; and in the traditional square energy absorption box, 4 main energy absorption and force transmission paths are usually arranged. Compared with the traditional square section energy absorption box, the cross section energy absorption box has the advantages that the absorbed collision energy is increased by about 15% -25%, the invasion of a power assembly to a passenger compartment is effectively reduced, the safety of passengers is protected, meanwhile, the damage to a motor, a speed reducer and a vehicle body in a front engine compartment is reduced, and the maintenance cost is reduced.
2. The cross-shaped internal high-pressure forming energy absorption box adopts an internal high-pressure forming process, and compared with an energy absorption box with a punching and welding structure, an over-hard area generated by buckling welding scrap edges (double material thickness and welding heat influence) is avoided; in addition, the reasonable convex ribs and the reasonable concave ribs are arranged on the upper end face, the lower end face, the left end face and the right end face of the cross-shaped surface of the energy absorption box and are used as collision inducing ribs, so that the energy absorption box with the cross-shaped inner high-pressure forming structure can be crushed step by step during collision energy absorption, the crushing form is regular and good in consistency, and the stability of the deformation posture of the whole vehicle is improved.
3. The cross-shaped internal high-pressure forming energy absorption box adopts an internal high-pressure forming process, and the cross-shaped section design, the drawing die angle and the round angle are reasonably arranged, so that the cross-shaped internal high-pressure forming energy absorption box has good manufacturability; the production process of the cross-shaped internal high-pressure forming energy absorption box comprises the following steps: fixed-length welding of tubes, internal high-pressure forming, saw cutting or laser cutting. If the production is carried out on a common working table top 2400mm-1600mm of small and medium-sized internal high-pressure forming equipment, at least one-die twelve-piece production can be realized, the production efficiency is high, and the material utilization rate can reach more than 95%; the energy absorption box with the common punching and welding structure is generally produced by one die and two pieces, and the material utilization rate is about 70-80 percent. Compared with an energy absorption box with a punching and welding structure, the energy absorption box is produced by adopting one die and a plurality of pieces through internal high-pressure forming, and the cost of the buckling and overlap welding process of stamping parts, the investment of welding tools and the weight of welding overlaps are saved; in conclusion, compared with the energy absorption box with a punching and welding structure, the cross-shaped inner high-pressure forming energy absorption box has the advantages that the cost is reduced by 15% -20%, and the weight is reduced by about 4% -6%.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the description of the embodiments of the present invention will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art that other drawings can be obtained according to the contents of the embodiments of the present invention and the drawings without creative efforts.
FIG. 1 is a schematic structural view of a cross-shaped internal high pressure forming energy absorption box of the present invention.
FIG. 2 is a schematic view of the main energy absorption path of the cross-shaped inner high pressure forming energy absorption box of the present invention.
Fig. 3 is a schematic view of the usage state of the present invention.
FIG. 4 is a schematic diagram of a prior art impact-welded energy-absorbing box.
FIG. 5 is a schematic view showing a production state of a one-mold multi-piece (one-mold twelve-piece) cross-shaped inner high-pressure forming energy absorption box according to the present invention.
Wherein: the energy absorption box comprises a cross-shaped inner high-pressure forming energy absorption box 1, an energy absorption box cover plate 2 with an inner higher than forming structure, a front auxiliary frame assembly 3, a first boss 4, a second boss 5, a third boss 6, a fourth boss 7, a first concave rib 8, a second concave rib 9, a convex rib 10, a die-splitting fillet 11, an existing stamping and welding structure energy absorption box 12, an existing stamping and welding structure energy absorption box cover plate 13, buckling and welding laps 14, 12 fillets comprising L1-L12, an existing stamping and welding structure energy absorption box main energy absorption force transmission path L1'-L4', an inner high-pressure forming shaft end process supplement 15 and a saw cutting or laser cutting position 16.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings and examples. It is to be understood that the specific embodiments described herein are merely illustrative of the invention and are not limiting of the invention. It should be further noted that, for the convenience of description, only some of the structures related to the present invention are shown in the drawings, not all of the structures.
In the description of the present invention, unless otherwise explicitly specified or limited, the terms "connected," "connected," and "fixed" are to be construed broadly and may, for example, be fixedly connected, detachably connected, or integral to one another; can be mechanically or electrically connected; either directly or indirectly through intervening media, either internally or in any other relationship. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
In the present invention, unless otherwise expressly stated or limited, "above" or "below" a first feature means that the first and second features are in direct contact, or that the first and second features are not in direct contact but are in contact with each other via another feature therebetween. Also, the first feature "on," "above" and "over" the second feature may include the first feature being directly above and obliquely above the second feature, or simply indicating that the first feature is at a higher level than the second feature. A first feature being "under," "below," and "beneath" a second feature includes the first feature being directly under and obliquely below the second feature, or simply meaning that the first feature is at a lesser elevation than the second feature.
In the description of the present embodiment, the terms "upper", "lower", "left", "right", and the like are used based on the orientations and positional relationships shown in the drawings only for convenience of description and simplification of operation, and do not indicate or imply that the referred device or element must have a specific orientation, be configured and operated in a specific orientation, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first" and "second" are used only for descriptive purposes and are not intended to have a special meaning.
Example 1
As shown in fig. 1-2, an integrated cross-shaped inner high-pressure forming energy absorption box structure of an electric vehicle subframe comprises a cross-shaped inner high-pressure forming energy absorption box 1 and an inner high-pressure forming energy absorption box cover plate 2; the cross-shaped inner high-pressure forming energy absorption box 1 is an integrated piece and has a cross-shaped closed cross-section structure; the upper end surface and the lower end surface of the cross-shaped internal high-pressure forming energy absorption box 1 are respectively provided with a first boss 4 and a second boss 5, and the left end surface and the right end surface of the cross-shaped internal high-pressure forming energy absorption box 1 are respectively provided with a third boss 6 and a fourth boss 7; the two ends of the protruding parts of the first boss 4, the second boss 5, the third boss 6 and the fourth boss 7 are respectively provided with a round angle, and the joint of every two adjacent bosses is also provided with a round angle, so that 12 round angles in total are arranged between L1 and L12, and 12 main energy absorption and force transmission paths are formed.
The fillet radii of 12 main energy absorption and force transmission paths (L1-L12) on the cross-shaped inner high-pressure forming energy absorption box are all 1.5 times of the thickness of the material, and the thickness of the material is the thickness of the material used by the cross-shaped inner high-pressure forming energy absorption box 1.
The ratio of the transverse width to the longitudinal height of the cross-shaped internal high-pressure forming energy absorption box 1 is 1:1.2, namely the ratio of the distance between the top surface of the upper first boss 4 and the bottom surface of the lower second boss 5 to the distance between the left end surface of the left third boss 6 and the right end surface of the right fourth boss 7.
The cross-shaped inner high-pressure forming energy absorption box 1 is provided with three first concave ribs 8 on the upper end surface and the lower end surface of the first boss 4 and the second boss 5 respectively; three convex ribs 10 are respectively arranged on the left end surface and the right end surface of the third boss 6 and the fourth boss 7; six second concave ribs 9 are respectively arranged on the upper end surface and the lower end surface of the third boss 6 and the fourth boss 7.
The depth of the concave ribs 8 and 9 is set to be 1.25 times of the material thickness, and the height of the convex rib 10 is the same as the depth of the first concave rib 8 and the second concave rib 9.
The maximum perimeter change rate of the cross-shaped inner high-pressure forming energy absorption box 1 along the section of the central axis is about 8%.
As shown in FIG. 3, in use, a cross-shaped inner high-pressure forming energy absorption box 1 is welded on a front cross beam of a front subframe assembly 3, and an inner high-pressure forming energy absorption box cover plate 2 is welded on the front end face of the cross-shaped inner high-pressure forming energy absorption box 1.
Example 2
Referring to fig. 1-2, an integrated cross-shaped inner high-pressure forming energy absorption box structure of an electric vehicle subframe is characterized in that the energy absorption box is of a cross-shaped closed cross-section structure and comprises a cross-shaped inner high-pressure forming energy absorption box 1 and an inner high-pressure forming energy absorption box cover plate 2; the cross-shaped inner high-pressure forming energy absorption box 1 is welded on a front cross beam of the front subframe assembly 3, and the inner high-pressure forming energy absorption box cover plate 2 is welded on the front end face of the cross-shaped inner high-pressure forming energy absorption box 1.
The cross-shaped inner high-pressure forming energy absorption box 1 is cross-shaped closed cross section, and 4 surface bosses are arranged on the upper, lower, left and right end surfaces of the cross-shaped inner high-pressure forming energy absorption box 1 in total; a fillet is arranged at the intersection of the plane of each boss and the vertical plane, and the fillet is 1.5 times of the material thickness, so that 12 main energy-absorbing and force-transmitting paths are formed; the cross-shaped inner high-pressure forming energy absorption box 1 has a section aspect ratio of about 1:1.2; compared with the traditional square-section energy absorption box, the energy absorption box has the advantages that the absorbed collision energy is increased by about 15-25%, the invasion of a power assembly to a passenger compartment is effectively reduced, the safety of passengers is protected, meanwhile, the damage to a motor, a speed reducer and a vehicle body in a front engine compartment is reduced, and the maintenance cost is reduced.
The cross-shaped inner high-pressure forming energy absorption box 1 is provided with three concave ribs 8 on the upper end surface and the lower end surface of the first boss 4 and the second boss 5 respectively; three convex ribs 10 are respectively arranged on the left and right end surfaces of the third boss 6 and the fourth boss 7; six concave ribs 9 are respectively arranged on the upper end surface and the lower end surface of the third boss 6 and the fourth boss 7; the depth of the concave ribs 8 and 9 is set to be 1.25 times of the material thickness, and the height of the convex rib 10 is the same as the depth of the concave ribs 8 and 9; the maximum perimeter change rate of the cross-shaped inner high-pressure forming energy absorption box 1 along the section of the central axis is about 8%.
The structure of the cross-shaped inner high-pressure forming energy absorption box 1 adopts an inner high-pressure forming process, and the cross-shaped section design has good manufacturability; the cross-shaped inner high-pressure forming energy absorption box 1 is provided with drawing angles on left and right end surface bosses, the upper and lower end surfaces are split at a symmetrical horizontal plane, and symmetrical drawing angles and split fillets 11 are arranged on a split line; compared with the energy absorption box with a punching and welding structure, an over-hard area caused by buckling welding lapping edges 14 (double material thickness and welding heat influence) is avoided; in addition, the reasonable convex ribs and the reasonable concave ribs are arranged on the upper end face, the lower end face and the left end face and the right end face of the cross-shaped surface of the energy absorption box and are used as collision inducing ribs, so that the cross-shaped inner high-pressure forming energy absorption box 1 can be crushed step by step during collision energy absorption, the crushing form is regular and good in consistency, and the stability of the deformation posture of the whole vehicle is improved.
As shown in FIG. 5, the production process of the cross-shaped inner high-pressure forming energy absorption box 1 comprises the following steps: fixed-length welding of the pipe, internal high-pressure forming and cutting (saw cutting or laser cutting), wherein 15 is the technological supplement of the internal high-pressure forming shaft end, and 16 is the saw cutting or laser cutting position. The production can be carried out on a common worktable surface of 2400mm x 1600mm of small and medium-sized internal high-pressure forming equipment, at least one-die twelve-piece production can be realized, the production efficiency is high, and the material utilization rate can reach more than 95 percent; the energy absorption box with the common punching and welding structure is generally produced by adopting one die and two pieces, so that the requirements of low cost and light weight are met, and the material utilization rate is about 70-80%.
Compared with an energy absorption box with a punching and welding structure, the energy absorption box is produced by adopting one die and a plurality of pieces through internal high-pressure forming, and the cost of the buckling and overlap welding process of stamping parts, the investment of welding tools and the weight of welding overlaps are saved; the cross-shaped inner high-pressure forming energy absorption box 1 is produced by adopting an inner high-pressure forming process, compared with an energy absorption box with a punching and welding structure, the cost is reduced by 15-20%, and the weight is reduced by about 4-6%.
Although the preferred embodiments of the present invention have been described in detail, it should be understood that the scope of the present invention is not limited to the details of the embodiments, and that any simple modifications within the technical scope of the present invention and the technical solutions and inventive concepts of the present invention can be substituted or changed by equivalents and changes by those skilled in the art within the technical scope of the present invention.
It should be noted that the various technical features described in the above embodiments can be combined in any suitable manner without contradiction, and the invention is not described in any way for the possible combinations in order to avoid unnecessary repetition.
In addition, any combination of the various embodiments of the present invention is also possible, and the same should be considered as the disclosure of the present invention as long as it does not depart from the spirit of the present invention.
Claims (6)
1. The integrated cross-shaped inner high-pressure forming energy absorption box structure of the electric vehicle subframe is characterized by comprising a cross-shaped inner high-pressure forming energy absorption box (1) and an inner high-pressure forming energy absorption box cover plate (2), wherein the cross-shaped inner high-pressure forming energy absorption box (1) is an integrated piece and is of a cross-shaped closed cross section structure, a first boss (4) and a second boss (5) are respectively arranged on the upper end surface and the lower end surface of the cross-shaped inner high-pressure forming energy absorption box (1), and a third boss (6) and a fourth boss (7) are respectively arranged on the left end surface and the right end surface of the cross-shaped inner high-pressure forming energy absorption box (1); the two ends of the protruding parts of the first boss (4), the second boss (5), the third boss (6) and the fourth boss (7) are respectively provided with a round angle, and the joint of every two adjacent bosses is also provided with a round angle, so that 12 round angles in total are arranged between L1 and L12, and 12 main energy-absorbing and force-transmitting paths are formed.
2. The integrated cross-shaped inner high-pressure forming energy absorption box structure of the electric vehicle subframe as claimed in claim 1, wherein the fillet radii of L1-L12 are all 1.5 times of material thickness.
3. The integrated cross-shaped inner high-pressure forming energy absorption box structure of the electric vehicle subframe as claimed in claim (1), wherein the ratio of the transverse width to the longitudinal height of the cross-shaped inner high-pressure forming energy absorption box (1) is 1:1.2.
4. the integrated cross-shaped inner high-pressure forming energy absorption box structure of the electric vehicle subframe as claimed in claim 1, wherein the cross-shaped inner high-pressure forming energy absorption box (1) is provided with three first concave ribs (8) on the upper end surface of the first boss (4) and the lower end surface of the second boss (5) respectively; three convex ribs (10) are respectively arranged on the left end surface of the third boss (6) and the right end surface of the fourth boss (7); six second concave ribs (9) are respectively arranged on the upper end surface of the third boss (6) and the lower end surface of the fourth boss (7).
5. The integrated cross-shaped inner high-pressure forming energy absorption box structure of the electric vehicle subframe as claimed in claim 4, wherein the depth of the first concave rib (8) and the second concave rib (9) is set to be 1.25 times of the material thickness, and the height of the convex rib (10) is the same as the depth of the first concave rib (8) and the second concave rib (9).
6. The integrated cross-shaped inner high-pressure forming energy absorption box structure of the electric vehicle subframe as claimed in claim 1, wherein the maximum perimeter change rate of the cross-shaped inner high-pressure forming energy absorption box (1) along the section of the central axis is about 8%.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210834429.5A CN115257931B (en) | 2022-07-14 | 2022-07-14 | Integrated cross-shaped internal high-pressure forming energy absorption box structure of electric vehicle auxiliary frame |
| PCT/CN2023/089957 WO2024011998A1 (en) | 2022-07-14 | 2023-04-22 | Integrated cross-shaped hydroformed crash box structure for electric vehicle subframe |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202210834429.5A CN115257931B (en) | 2022-07-14 | 2022-07-14 | Integrated cross-shaped internal high-pressure forming energy absorption box structure of electric vehicle auxiliary frame |
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| CN115257931A true CN115257931A (en) | 2022-11-01 |
| CN115257931B CN115257931B (en) | 2024-05-10 |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2024011998A1 (en) * | 2022-07-14 | 2024-01-18 | 一汽奔腾轿车有限公司 | Integrated cross-shaped hydroformed crash box structure for electric vehicle subframe |
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| CN115257931B (en) | 2024-05-10 |
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