CN115257931B - Integrated cross-shaped internal high-pressure forming energy absorption box structure of electric vehicle auxiliary frame - Google Patents
Integrated cross-shaped internal high-pressure forming energy absorption box structure of electric vehicle auxiliary frame Download PDFInfo
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- CN115257931B CN115257931B CN202210834429.5A CN202210834429A CN115257931B CN 115257931 B CN115257931 B CN 115257931B CN 202210834429 A CN202210834429 A CN 202210834429A CN 115257931 B CN115257931 B CN 115257931B
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- 238000010521 absorption reaction Methods 0.000 title abstract description 42
- 239000000463 material Substances 0.000 claims description 21
- 230000008859 change Effects 0.000 claims description 4
- 230000005540 biological transmission Effects 0.000 abstract description 8
- 238000003466 welding Methods 0.000 description 24
- 238000004519 manufacturing process Methods 0.000 description 11
- 238000000034 method Methods 0.000 description 8
- 229910000831 Steel Inorganic materials 0.000 description 6
- 238000004080 punching Methods 0.000 description 6
- 239000010959 steel Substances 0.000 description 6
- 238000005520 cutting process Methods 0.000 description 5
- 230000008569 process Effects 0.000 description 5
- 229910000838 Al alloy Inorganic materials 0.000 description 4
- 238000003698 laser cutting Methods 0.000 description 4
- 238000012423 maintenance Methods 0.000 description 3
- 239000000956 alloy Substances 0.000 description 2
- 239000003638 chemical reducing agent Substances 0.000 description 2
- 230000006698 induction Effects 0.000 description 2
- 230000009545 invasion Effects 0.000 description 2
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- 239000013589 supplement 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 vehicles, and particularly relates to an integrated cross-shaped internal high-pressure forming energy-absorbing box structure of an auxiliary frame of an electric vehicle; comprises a cross-shaped inner high-pressure forming energy-absorbing box and an inner high-pressure forming energy-absorbing box cover plate; the cross-shaped inner high-pressure forming energy-absorbing box is an integral piece and is of a cross-shaped closed section structure; the upper end face and the lower end face of the energy-absorbing box main body are respectively provided with a first boss and a second boss, and the left end face and the right end face are respectively provided with a third boss and a fourth boss; the joint of adjacent bosses on the energy absorption box main body is provided with 12 rounded corners in total, so that 12 main energy absorption and transmission 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 vehicles, and particularly relates to an integrated cross-shaped internal high-pressure forming energy-absorbing box structure of an electric vehicle auxiliary frame.
Background
The automobile energy absorption box is taken 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 weight of the electric vehicle is larger than that of 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 front auxiliary frame cross beam, so that the collision safety is further improved; the energy absorption box is used as a passive safety protection system, so that the energy absorption box can effectively absorb collision energy when a vehicle collides, the safety of passengers in the vehicle can be effectively protected, and the damage of the collision force to a power assembly and a vehicle body in a front cabin can be 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 crushing deformation stability, light weight and low cost; however, the conventional energy absorption box has the following problems:
1. the aluminum alloy energy-absorbing box has the advantages that the light weight effect is improved, but the aluminum alloy material has higher cost compared with the steel material, and in addition, the aluminum alloy energy-absorbing box has lower energy absorption due to the elastic modulus characteristic relation between the aluminum alloy material and the steel material;
2. The steel energy-absorbing box is generally square in section, four main energy-absorbing force transmission paths are arranged on the steel energy-absorbing box, and the four main energy-absorbing force transmission paths are respectively arranged at four corners of the steel energy-absorbing box, such as L1'-L4' in FIG. 4, and the aspect ratio of the square section is generally set to be 1:1, a step of; in order to increase the energy absorption performance, the collision energy absorption performance is generally improved by increasing the thickness of the material and the length or the perimeter of the section of the energy absorption box, but the problems of heavy weight and high cost exist;
3. In general, the steel energy-absorbing box adopts a punching and welding structure, and buckling and welding overlap edges 14 (double material thickness and welding heat influence) generate an excessively hard area, so that the crushing form is irregular and the deformation consistency is poor in collision due to the manufacturing process, and the collision deformation stability of the whole automobile is influenced.
Disclosure of Invention
In order to overcome the problems, the invention provides an integrated cross-shaped internal high-pressure forming energy-absorbing box structure of an electric vehicle auxiliary frame, which can realize high collision energy absorption and high collision deformation stability of parts and has the advantages of low cost and light weight.
The integrated cross-shaped inner high-pressure forming energy-absorbing box structure of the auxiliary frame of the electric vehicle comprises a cross-shaped inner high-pressure forming energy-absorbing box 1 and an inner high-pressure forming energy-absorbing box cover plate 2, wherein the cross-shaped inner high-pressure forming energy-absorbing box 1 is an integral 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 face and the lower end face of the cross-shaped inner high-pressure forming energy-absorbing box 1, and a third boss 6 and a fourth boss 7 are respectively arranged on the left end face and the right end face of the cross-shaped inner high-pressure forming energy-absorbing 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 round corners, and the joint part of every two adjacent bosses is also provided with round corners, so that 12 round corners are arranged in total from L1 to L12, thereby forming 12 main energy absorption and force transmission paths.
The radius of the round angle of the L1-L12 is 1.5 times of the thickness of the material.
The transverse width and longitudinal height ratio of the cross-shaped inner high-pressure forming energy absorption box 1 is 1:1.2.
The cross-shaped inner high-pressure forming energy-absorbing box 1 is provided with three first concave ribs 8 on the upper end face of the first boss 4 and the lower end face of the second boss 5 respectively; three convex ribs 10 are respectively arranged on the left end face of the third boss 6 and the right end face of the fourth boss 7; six second concave ribs 9 are respectively arranged on the upper end face of the third boss 6 and the lower end face of the fourth boss 7.
The depth of the first concave ribs 8 and the second concave ribs 9 is 1.25 times of the material thickness, and the height of the convex ribs 10 is the same as the depth of the first concave ribs 8 and the second concave ribs 9.
The maximum perimeter change rate of the cross-shaped inner high-pressure forming energy absorption box 1 along the central axis section is about 8%.
The invention has the beneficial effects that:
1. The cross-shaped inner high-pressure forming energy-absorbing box is of a cross-shaped closed cross-section structure, and 4 bosses are arranged on the upper end face, the lower end face, the left end face and the right end face of the energy-absorbing box main body in a total mode; a round corner is arranged at the intersection of the plane and the vertical plane of each boss, so that 12 main energy-absorbing force-transferring paths are formed; and the traditional square energy absorption box is generally provided with 4 main energy absorption and transmission paths. Compared with the traditional square section energy-absorbing box, the cross section energy-absorbing box has the advantages that the absorption collision energy is increased by about 15% -25%, the invasion of the power assembly to the passenger cabin is effectively reduced, the safety of passengers is protected, the damage to the motor, the speed reducer and the vehicle body in the front cabin is reduced, and the maintenance cost is reduced.
2. Compared with the energy-absorbing box with a stamping structure, the cross-shaped inner high-pressure forming energy-absorbing box has no excessively hard area generated by buckling welding overlap edges (double material thickness and welding heat influence); 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 and serve as collision induction ribs, so that the energy-absorbing 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 the uniformity is good, so that the stability of the deformation posture of the whole vehicle is improved.
3. The cross-shaped inner high-pressure forming energy-absorbing box adopts an inner high-pressure forming process, and the design of a cross-shaped section, a draft angle and a round angle are reasonably arranged, so that the energy-absorbing box has good manufacturability; the production process of the cross-shaped inner high-pressure forming energy-absorbing box comprises the following steps: fixed-length welded pipe, internal high-pressure forming, saw cutting or laser cutting. If the material is produced on a common working table 2400mm or 160 mm of a small and medium-sized internal high-pressure forming device, at least one-die twelve-piece production can be realized, the production efficiency is high, and the material utilization rate can be up to more than 95%; the energy absorption box with the common punching and welding structure is generally produced by adopting one die and two pieces, and the material utilization rate is generally about 70-80%. Compared with the energy-absorbing box with a stamping and welding structure, the energy-absorbing box adopts the production of forming one die with multiple pieces at high pressure, and saves the cost of the stamping part buckling scrap welding procedure, the welding tooling investment and the welding scrap weight; in conclusion, compared with the energy-absorbing box with a stamping and welding structure, the cross-shaped inner high-pressure forming energy-absorbing box has the advantages that the cost is reduced by 15% -20%, and the weight is reduced by 4% -6%.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following description will briefly explain the drawings to be used in the description of the embodiments of the present invention, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and other drawings may be obtained according to the contents of the embodiments of the present invention and these drawings without inventive effort for those skilled in the art.
FIG. 1 is a schematic view of a cross-shaped inner high-pressure forming energy-absorbing box structure of the invention.
FIG. 2 is a schematic diagram of the main energy absorption path of the cross-shaped inner high-pressure forming energy absorption box.
FIG. 3 is a schematic view of the present invention in use.
FIG. 4 is a schematic view of a prior art energy absorber box with a punch welded structure.
FIG. 5 is a schematic view showing the production state of the cross-shaped inner high-pressure forming energy-absorbing box with one mold and multiple pieces (twelve pieces).
Wherein: the energy-absorbing box comprises a cross-shaped inner high-pressure forming energy-absorbing box 1, an inner higher-than forming structure energy-absorbing box cover plate 2, 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 parting round angle 11, an existing punching and welding structure energy-absorbing box 12, an existing punching and welding structure energy-absorbing box cover plate 13, a buckling welding overlap edge 14, 12 round angles in total of L1-L12, an existing punching and welding structure energy-absorbing box main energy-absorbing 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 invention is described in further detail below with reference to the drawings and examples. It is to be understood that the specific embodiments described herein are merely illustrative of the invention and are not limiting thereof. It should be further noted that, for convenience of description, only some, but not all of the structures related to the present invention are shown in the drawings.
In the description of the present invention, unless explicitly stated and limited otherwise, the terms "connected," "connected," and "fixed" are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally formed; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communicated with the inside of two elements or the interaction relationship of the two elements. The specific meaning of the above terms in the present invention will be understood in specific cases by those of ordinary skill in the art.
In the present invention, unless expressly stated or limited otherwise, a first feature "above" or "below" a second feature may include both the first and second features being in direct contact, as well as the first and second features not being in direct contact but being in contact with each other through additional features therebetween. Moreover, a first feature being "above," "over" and "on" a second feature includes the first feature being directly above and obliquely above the second feature, or simply indicating that the first feature is higher in level than the second feature. The first feature being "under", "below" and "beneath" the second feature includes the first feature being directly under and obliquely below the second feature, or simply means that the first feature is less level than the second feature.
In the description of the present embodiment, the terms "upper", "lower", "left", "right", and the like are orientation or positional relationships based on those shown in the drawings, merely for convenience of description and simplicity of operation, and do not indicate or imply that the apparatus or elements referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as limiting the invention. Furthermore, the terms "first," "second," and the like, are used merely for distinguishing between descriptions and not for distinguishing between them.
Example 1
As shown in fig. 1-2, an integrated cross-shaped inner high-pressure forming energy-absorbing box structure of an electric vehicle auxiliary frame comprises a cross-shaped inner high-pressure forming energy-absorbing box 1 and an inner high-pressure forming energy-absorbing box cover plate 2; the cross-shaped inner high-pressure forming energy absorption box 1 is an integral piece and is of a cross-shaped closed cross-section structure; the upper end face and the lower end face of the cross-shaped inner high-pressure forming energy-absorbing box 1 are respectively provided with a first boss 4 and a second boss 5, and the left end face and the right end face of the cross-shaped inner high-pressure forming energy-absorbing 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 round corners, and the joint part of every two adjacent bosses is also provided with round corners, so that 12 round corners are arranged in total from L1 to L12, thereby forming 12 main energy absorption and force transmission paths.
The radius of the round angle of the 12 main energy absorption and transmission paths (L1-L12) is 1.5 times of the thickness of the material, and the thickness of the material refers to the thickness of the material used for the cross-shaped inner high-pressure forming energy absorption box 1.
The transverse width and longitudinal height ratio of the cross-shaped inner high-pressure forming energy absorption box 1 is 1:1.2, i.e. 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-absorbing box 1 is provided with three first concave ribs 8 on the upper end face and the lower end face of the first boss 4 and the second boss 5 respectively; three convex ribs 10 are respectively arranged on the left end face and the right end face of the third boss 6 and the fourth boss 7; six second concave ribs 9 are respectively arranged on the upper end face and the lower end face 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 central axis section is about 8%.
As shown in fig. 3, in use, the cross-shaped inner high-pressure forming energy-absorbing box 1 is welded on the front cross beam of the front auxiliary frame assembly 3, and the inner high-pressure forming energy-absorbing box cover plate 2 is welded on the front end face of the cross-shaped inner high-pressure forming energy-absorbing box 1.
Example 2
Referring to fig. 1-2, an integrated cross-shaped internal high-pressure forming energy-absorbing box structure of an electric vehicle auxiliary frame, wherein the energy-absorbing box is of a cross-shaped closed cross-section structure and comprises a cross-shaped internal high-pressure forming energy-absorbing box 1 and an internal high-pressure forming energy-absorbing box cover plate 2; the cross-shaped inner high-pressure forming energy-absorbing box 1 is welded on the front cross beam of the front auxiliary frame assembly 3, and the inner high-pressure forming energy-absorbing box cover plate 2 is welded on the front end face of the cross-shaped inner high-pressure forming energy-absorbing box 1.
The cross section of the cross-shaped inner high-pressure forming energy-absorbing box 1 is a cross-shaped closed cross section, 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 cross-shaped inner high-pressure forming energy-absorbing box 1 in a total mode; a fillet is arranged at the intersection of the plane and the vertical plane of each boss, and the fillet is 1.5 times of the thickness of the material, so that 12 main energy-absorbing and force-transferring paths are formed; the cross-section aspect ratio of the cross-shaped inner high-pressure forming energy-absorbing box 1 is set to be about 1:1.2; compared with the traditional square section energy-absorbing box, the energy-absorbing box has the advantages that the absorption collision energy is increased by about 15% -25%, the invasion of the power assembly to the passenger cabin is effectively reduced, the safety of passengers is protected, the damage to the motor, the speed reducer and the vehicle body in the front cabin is reduced, and the maintenance cost is reduced.
Three concave ribs 8 are respectively arranged on the upper end face and the lower end face of the first boss 4 and the second boss 5 of the cross-shaped inner high-pressure forming energy-absorbing box 1; three convex ribs 10 are respectively arranged on the left end face and the right end face of the third boss 6 and the fourth boss 7; six concave ribs 9 are respectively arranged on the upper end face and the lower end face 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 thickness of the material, 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 central axis section is about 8%.
The structure of the cross-shaped inner high-pressure forming energy-absorbing box 1 adopts an inner high-pressure forming process, and the cross-shaped section design has good manufacturability; the method comprises the steps that drawing die angles are arranged on bosses on the left end face and the right end face of the cross-shaped inner high-pressure forming energy-absorbing box 1, dies are separated from horizontal planes symmetrical to the upper end face and the lower end face, and symmetrical drawing die angles and die separation fillets 11 are arranged on a die separation line; compared with the energy absorption box with the impact welding structure, the energy absorption box has no excessively hard area caused by the buckling welding overlap edge 14 (double material thickness and welding heat influence); 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 and serve as collision induction ribs, so that the cross-shaped inner high-pressure forming energy-absorbing box 1 can be crushed step by step during collision energy absorption, the crushing form is regular, the consistency is good, 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 is as follows: fixed-length welded pipe, internal high-pressure forming and cutting (saw cutting or laser cutting), 15 is the process supplement of the internal high-pressure forming shaft end, and 16 is the saw cutting or laser cutting position. The production is carried out on a common working table surface 2400mm or 1600mm of a small and medium-sized internal high-pressure forming device, at least one-die twelve-piece production can be realized, the production efficiency is high, and the material utilization rate can be up to more than 95%; the energy absorption box with the common impact welding structure is generally produced by adopting one die and two parts, so that the requirements of low cost and light weight are met, and the material utilization rate is generally about 70-80%.
Compared with the energy-absorbing box with a stamping and welding structure, the energy-absorbing box adopts the production of forming one die with multiple pieces at high pressure, and saves the cost of the stamping part buckling scrap welding procedure, the welding tooling investment and the welding scrap weight; the cross-shaped inner high-pressure forming energy-absorbing box 1 is produced by adopting an inner high-pressure forming process, and compared with the energy-absorbing box with a punching and welding structure, the cost is reduced by 15-20%, and the weight is reduced by about 4-6%.
The preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings, but the scope of the present invention is not limited to the specific details of the above embodiments, and within the scope of the technical spirit of the present invention, any person skilled in the art may apply equivalent substitutions or alterations to the technical solution of the present invention and the inventive concept thereof within the scope of the technical spirit of the present invention, and these simple modifications are all within the scope of the present invention.
In addition, the specific features described in the above embodiments may be combined in any suitable manner, and in order to avoid unnecessary repetition, various possible combinations are not described further.
Moreover, any combination of the various embodiments of the invention can be made without departing from the spirit of the invention, which should also be considered as disclosed herein.
Claims (1)
1. The integrated cross-shaped inner high-pressure forming energy-absorbing box structure of the auxiliary frame of the electric vehicle is characterized by comprising a cross-shaped inner high-pressure forming energy-absorbing box (1) and an inner high-pressure forming energy-absorbing box cover plate (2), wherein the cross-shaped inner high-pressure forming energy-absorbing 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 face and the lower end face of the cross-shaped inner high-pressure forming energy-absorbing box (1), and a third boss (6) and a fourth boss (7) are respectively arranged on the left end face and the right end face of the cross-shaped inner high-pressure forming energy-absorbing box (1); the two ends of the convex parts of the first boss (4), the second boss (5), the third boss (6) and the fourth boss (7) are respectively provided with round corners, and the joint part of every two adjacent bosses is also provided with round corners, so that 12 round corners are arranged in total, namely L1-L12, so that 12 main energy-absorbing force-transferring paths are formed;
The radius of the round angle of the L1-L12 is 1.5 times of the thickness of the material;
The transverse width and longitudinal height ratio of the cross-shaped inner high-pressure forming energy-absorbing box (1) is 1:1.2;
Three first concave ribs (8) are respectively arranged on the upper end face of the first boss (4) and the lower end face of the second boss (5) of the cross-shaped inner high-pressure forming energy-absorbing box (1); three convex ribs (10) are respectively arranged on the left end face of the third boss (6) and the right end face of the fourth boss (7); six second concave ribs (9) are respectively arranged on the upper end face of the third boss (6) and the lower end face of the fourth boss (7);
the depth of the first concave ribs (8) and the depth of the second concave ribs (9) are 1.25 times of the material thickness, and the height of the convex ribs (10) is the same as the depth of the first concave ribs (8) and the second concave ribs (9);
The maximum perimeter change rate of the cross-shaped inner high-pressure forming energy-absorbing box (1) along the central axis section is about 8%.
Priority Applications (2)
| 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 |
| 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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| 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 CN115257931A (en) | 2022-11-01 |
| CN115257931B true CN115257931B (en) | 2024-05-10 |
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| CN115257931B (en) * | 2022-07-14 | 2024-05-10 | 一汽奔腾轿车有限公司 | Integrated cross-shaped internal high-pressure forming energy absorption box structure of electric vehicle auxiliary frame |
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| WO2024011998A1 (en) | 2024-01-18 |
| CN115257931A (en) | 2022-11-01 |
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