CN116198145A - Manufacturing method of automobile lightweight composite auxiliary frame - Google Patents

Abstract

The manufacturing approach of a car light-weight composite auxiliary frame, fix a plurality of winding end points with the tool first, then twine into a annular reinforcement along winding end point with the continuous fiber, then form the composite material and enclose by a plurality of crossbeams on the reinforcement and form the annular structure, finally form the auxiliary frame after the crossbeam presses into the spherical hinge; and when in winding, the continuous fiber is wound between two adjacent winding end points to form a segmented winding structure, and each segmented winding structure is connected into a whole through the winding end points. The auxiliary frame obtained through the mode of winding and forming firstly has higher precision and higher bearing capacity, can greatly reduce the weight of the reinforcing body, can conveniently adjust the structure of the auxiliary frame, and meets different shape requirements.

Description

Manufacturing method of automobile lightweight composite auxiliary frame

Technical Field

The utility model relates to a manufacturing method of an auxiliary frame, in particular to a manufacturing method of an automobile light composite auxiliary frame.

Background

The auxiliary frame is a bracket for supporting front and rear axles and hanging, and can play a role in blocking vibration and noise and reducing the vibration and noise from directly entering a carriage. The auxiliary frame is more convenient to install and more important, and improves the comfort and suspension rigidity of the automobile. The subframe is generally formed by stamping and welding steel plates in the initial stage of birth, and has the advantages of complex structure, multiple working procedures, low processing precision and large weight. The current auxiliary frame is generally formed by adopting aluminum alloy for integral die casting, and compared with sheet metal parts, the weight is reduced, the precision is improved, but the current light-weight requirement cannot be met, and particularly for new energy automobiles, the light-weight requirement is higher.

The utility model discloses an integrated rear auxiliary frame manufactured by an aluminum alloy low-pressure hollow casting process, and discloses an utility model patent with the name of 'a rear auxiliary frame of an electric automobile low-pressure hollow camel beam bending structure'. The patent application with the application number of CN201810847505.X, named as a rear subframe assembly and a vehicle, discloses a rear subframe assembly supported by aluminum alloy.

The above documents are all made of aluminum alloy, the weight of the subframe is still to be further reduced, and the shape adjustment difficulty of the subframe made of aluminum alloy material is high, and the universality is not high.

Disclosure of Invention

The utility model provides a manufacturing method of an automobile light composite auxiliary frame aiming at the problems, which can not only greatly reduce the weight of a reinforcement body, but also conveniently adjust the structure of the auxiliary frame and meet different shape requirements.

The manufacturing approach of a car light-weight composite auxiliary frame, fix a plurality of winding end points with the tool first, then twine into a annular reinforcement along winding end point with the continuous fiber, then form the composite material and enclose by a plurality of crossbeams on the reinforcement and form the annular structure, finally form the auxiliary frame after the crossbeam presses into the spherical hinge; and when in winding, the continuous fiber is wound between two adjacent winding end points to form a segmented winding structure, and each segmented winding structure is connected into a whole through the winding end points.

Further, the winding endpoint includes metal bush, connecting bush and linking bridge, and metal bush sets up the position department of ball pivot on the sub vehicle frame, and connecting bush sets up the position department that is close to the centre in the sub vehicle frame crossbeam, and the linking bridge setting is in the position department that adjacent crossbeam connects. The winding end point is used as the tail end of continuous fiber winding, and the position of the continuous fiber is fixed to determine the shape of the reinforcement body and further determine the outline shape of the auxiliary frame.

Further, the metal bushing and the connecting bushing are positioned by inserting the through holes of the metal bushing and the connecting bushing into the fixed shaft of the tool, and the connecting bracket is adsorbed on the electromagnetic chuck of the tool for positioning.

Further, when the composite material is molded, a metal insert is arranged in a molding die to serve as a structure for connecting the auxiliary frame with the vehicle. When the auxiliary frame is mounted on the automobile, the auxiliary frame is mounted and fixed on the automobile through a spherical hinge pressed into a metal bushing and a metal insert molded on the composite material.

Further, the shape of the reinforcement is adjusted by adjusting the position of the connecting bush, thereby adjusting the outer shape of the subframe. Therefore, the auxiliary frames with different shapes can be easily designed and processed, and the research and development period is shortened for the requirements of different auxiliary frame shapes of different vehicle types.

Further, the connecting support is of a frame type three-dimensional structure formed by a plurality of edges, and continuous fibers at different cross beams are wound on the connecting edges of the connecting support in different directions.

Further, the connecting support is a frame structure formed by connecting two parallel triangular supports, and continuous fibers at different cross beams are wound on connecting edges of the triangular supports in different directions.

Further, the continuous fibers at the same cross beam are crossly wound on the connecting edges of the two triangular supports in the same direction.

Further, the continuous fibers are surface treated with a silane coupling agent prior to winding into a reinforcement.

Further, the front beam is provided with a 'rice' -shaped reinforcing rib structure on the surface facing the front.

Further, the front beam surface, the rear beam surface, the left side beam surface and the right side beam surface facing the top are provided with material escaping holes. And the other surfaces are continuous surfaces, so that the surface strength of the stressed surface during bearing is ensured.

Further, the composite body adopts a vacuum infusion or monomer in-situ polymerization process.

The beneficial effects of the utility model are as follows:

1. the utility model adopts the mode that the reinforcement is wound out firstly to serve as the supporting framework of the auxiliary frame, and then the composite material is coated outside the reinforcement, so that the weight of the auxiliary frame is greatly reduced; and when winding the reinforcing body, utilize frock location a plurality of winding endpoints as the intermediate junction spare when winding, make the reinforcing body be the structure of segmentation connection, even make the reinforcing body twine compacter, be difficult for the deformation, but also can conveniently change the shape of sub vehicle frame through adjusting the position of winding endpoint simultaneously, increase structural design degree of freedom, designability is high, be applicable to the three-dimensional space composite body structure of preparation complicacy, and guarantee that the structure can satisfy the complex outward appearance of composite body when bearing big load.

2. According to the utility model, the connecting bush is arranged at the middle part close to the cross beam, so that the center distance and the mounting precision of the product are ensured by controlling the position of the connecting bush, and the overall quality of the auxiliary frame is improved.

3. The utility model adopts the metal bushing and the connecting bushing to play a role of fixed connection so as to control the frame shape of the auxiliary frame, the closed structure formed by winding bears main load, the complex appearance structure and various different interface size structures are molded by utilizing the composite material, and the finally formed auxiliary frame has high precision and high bearing capacity.

Drawings

FIG. 1 is a schematic view of a subframe structure from the front;

FIG. 2 is a schematic view of the subframe structure from the rear;

FIG. 3 is a schematic view of the subframe structure as seen from above;

FIG. 4 is a schematic view of a reinforcement structure after winding according to an embodiment;

FIG. 5 is an enlarged schematic view of a portion of FIG. 4;

FIG. 6 is a schematic view of a connecting bushing according to an embodiment;

FIG. 7 is a schematic view of a connecting bracket according to an embodiment;

FIG. 8 is a schematic view of a metal bushing according to an embodiment;

FIG. 9 is a schematic diagram of a continuous fiber wound into a reinforcement after fixing winding end points in the tooling of the second embodiment;

FIG. 10 is a schematic structural view of a fixture with a winding end point fixed thereon according to the second embodiment;

FIG. 11 is a schematic diagram of the overall structure of a tooling according to the second embodiment;

FIG. 12 is a schematic structural view of a fixing connection bracket on a tooling of the second embodiment;

FIG. 13 is a schematic view of a metal bushing and a connecting bushing on a tooling for fixing a left side beam in the second embodiment;

FIG. 14 is a schematic view of a metal bushing at a fixed front beam of a tooling according to the second embodiment;

in the figure: 1. metal bushing 11, metal outer sleeve 12, rubber vulcanizate 13, metal inner sleeve 2, connecting bushing 3, connecting bracket 311, upper connecting plate one 312, upper connecting plate two 313, upper connecting plate three 321, middle connecting plate one 322, middle connecting plate two 323, middle connecting plate three 331, lower connecting plate one 332, lower connecting plate two 333, lower connecting plate three 4, metal insert 5, continuous fiber 6, base 611, column one 612, support column one 613, slide rail one 614, cylinder one 615, electromagnetic chuck 616, power switch 621, column two 622, support column two 623, slide rail two 624, cylinder two 625, fixed shaft two 631, first slide rail three 632, cylinder three 633, second slide rail three, 634, support column three 635, fixed shaft three, 641, side rail four, 643, support column four 644, cylinder four, fixed shaft four, front beam 101, rear beam 102, side beam 103, left side beam 104 and right side beam.

Detailed Description

The utility model is further described below with reference to the accompanying drawings. Wherein the drawings are for illustrative purposes only and are shown in schematic, non-physical, and not intended to be limiting of the present patent; for the purpose of better illustrating embodiments of the utility model, certain elements of the drawings may be omitted, enlarged or reduced and do not represent the size of the actual product; it will be appreciated by those skilled in the art that certain well-known structures in the drawings and descriptions thereof may be omitted.

Example 1

In the present embodiment, the four cross members are referred to as a front member 101, a rear member 102, a left side member 103, and a right side member 104, respectively, from the perspective of the vehicle from the front side thereof, depending on the mounting of the subframe to the rear of the vehicle. The positional references to front, rear, top refer to the sub-frame being mounted to the vehicle, with each direction being measured from the perspective of the vehicle in the front of the vehicle.

In the manufacturing method of the automobile lightweight composite auxiliary frame, as shown in fig. 1-3, the auxiliary frame of the embodiment is of a closed frame structure surrounded by four cross beams of a front beam 101, a rear beam 102, a left side beam 103 and a right side beam 104, two metal bushings 1 are arranged at two ends of the front beam 101, one metal bushing 1 is arranged at each of the left side beam 103 and the right side beam 104 close to the rear beam 102, and metal inserts 4 are arranged at other parts of the auxiliary frame, which are connected with the automobile.

The manufacturing method comprises the following steps: first, as shown in fig. 4, each metal bush 1 is fixed to a subframe by a tool, one connecting bracket 3 is fixed to each of the front side member 101, the left side member 103, and the right side member 104, and the rear side member 102, and the left side member 103, and the right side member 104, and one connecting bush 2 is fixed to each of the intermediate positions of the left side member 103 and the right side member 104. And then winding the continuous fiber 5 by taking the metal bushing 1, the connecting bushing 2 and the connecting bracket 3 as winding supporting points to form a closed annular reinforcement body serving as a supporting structure of the auxiliary frame. After winding, the reinforcement is moved into the mould and the metal inserts 4 are fixed at other connecting parts of the subframe, and the composite material is filled to form the required subframe product.

The continuous fiber can be glass fiber, carbon fiber or basalt fiber, and the like, and the continuous fiber is subjected to surface treatment by using a silane coupling agent in advance before winding, and the composite material can be thermoplastic resin or thermosetting resin, is prepared by vacuum infusion or monomer in-situ polymerization process, can be medium-low pressure vacuum infusion, high-pressure vacuum infusion or high-pressure vacuum injection monomer in-situ polymerization, and depends on the performance requirements of the product. Better load bearing properties are provided by the reinforcement, while thermosetting or thermoplastic resins can be molded into complex appearances and attachment structures.

As shown in fig. 8, the metal bushing 1 is formed by vulcanizing and connecting the metal outer sleeve 11 and the metal inner sleeve 13 by adopting the rubber vulcanizing body 12, in the using process of the auxiliary frame, the spherical hinge is pressed into the metal inner sleeve 13, when the spherical hinge is damaged and needs to be replaced, the old spherical hinge can be pressed out of the metal inner sleeve 13 and then pressed into the new spherical hinge, and the whole auxiliary frame does not need to be replaced, so that the service life of the auxiliary frame is prolonged, and the production cost is reduced.

The connecting bush 2 is preferably of a metal construction, as shown in fig. 6, and may be of an i-shaped cylindrical construction or other construction, generally of a small size, so as to be able to be encased within the composite material of the left and right side members 103, 104. The shape of the reinforcement body can be changed by adjusting the position of the connecting bushing 2 in the three-dimensional space, so that the reinforcement body is designed into auxiliary frames with different shapes, the degree of freedom of structural design is increased, more application scenes are applicable, and the structure is ensured to bear a large load and simultaneously meet the complex appearance of the composite material body. Meanwhile, the positions of the connecting bushings are fixed through the tool in the winding process, so that the center distance and the mounting precision of products can be better controlled, and the overall quality of the auxiliary frame is improved.

As shown in fig. 7, in this embodiment, the connecting bracket 3 is a frame structure formed by connecting two parallel triangular brackets, namely: the first upper connecting plate 311, the second upper connecting plate 312 and the third upper connecting plate 313 enclose a triangular support, the first lower connecting plate 331, the second lower connecting plate 332 and the third lower connecting plate 333 enclose another triangular support, the two triangular supports are placed in parallel up and down, and the first middle connecting plate 321, the second middle connecting plate 322 and the third middle connecting plate 323 connect the two triangular supports at three corners. Of course, the connecting bracket 3 may be other frame structures, such as a structure for connecting two quadrangular frames, and the like.

The metal bushing 1, the connecting bushing 2 and the connecting bracket 3 are all used as end points of winding during the winding process. As shown in fig. 4, for the structure of the reinforcement at the front beam 101, the continuous fibers 5 respectively take two metal bushings 1 as winding end points, take one connecting bracket 3 and one metal bushing 1 as winding end points, and form an integral structure composed of three sections between the connecting bracket 3 and the metal bushing 1, between the two metal bushings 1, and between the metal bushing 1 and the connecting bracket 3. Accordingly, the left side member 103 and the right side member 104 each form an integral structure of three sections between the connecting bracket 3 and the metal spherical hinge 1, between the metal spherical hinge 1 and the connecting bush 2, and between the connecting bush 2 and the connecting bracket 3. By adopting sectional winding, the span of continuous fiber winding is shortened, the fiber is ensured to have constant tension and stable structure, and the quality of the auxiliary frame is further improved.

As shown in fig. 7, in this embodiment, the two triangular supports of the connecting support 3 are isosceles triangles with an angle approaching or equal to ninety degrees, and the lengths of the upper connecting plate one 311 and the upper connecting plate two 312 are equal, the included angle is a right angle or approximately a right angle, and the lengths of the lower connecting plate one 331 and the lower connecting plate three 332 are equal, and the included angle is a right angle or approximately a right angle. When the continuous fiber 5 is wound around the connecting bracket 3, as shown in fig. 5, when the connecting bracket 3 is located at the junction of the front beam 101 and the left side beam 103, the continuous fiber 5 from the direction of the front beam 101 is wound around the upper connecting plate one 311 and the lower connecting plate one 331, and preferably is wound in a staggered manner, and the upper winding round is wound around the upper connecting plate one 311 and the lower winding round is wound around the lower connecting plate one 331; the continuous fibers 5 from the left side member 103 are wound around the upper connecting plate two 312 and the lower connecting plate two 332, and it is also preferable to wind them alternately. The wrapping between the front beam 101 and the right side beam 104, the wrapping between the rear beam 102 and the left side beam 103, and the wrapping between the rear beam 102 and the right side beam 103 are all in a similar manner. Because sub vehicle frame in this embodiment is quadrilateral structure, the contained angle between the adjacent crossbeam is close the right angle, and the reinforcing body that twines like this can guarantee the shape of sub vehicle frame better. The upper connection plate three 313, the lower connection plate three 333, the middle connection plate one 321, the middle connection plate two 322 and the middle connection plate three 333 can be used as reserved connection points, and when the subframe needs to be designed into other shapes, continuous fibers 5 at other positions need to be connected to the intersection points of the cross beams, the connection points can be wound.

Meanwhile, in the forming process, the front beam 101 is provided with a reinforcing rib in a shape of a Chinese character 'mi' on the surface facing the front, the rear beam 102 is provided with a material escaping hole on the surface facing the rear, and the left side beam 103 and the right side beam 104 are also provided with material escaping holes on the surface facing the upper, so that the weight is reduced as much as possible on the premise of ensuring the overall strength of the auxiliary frame. The surfaces of the front beam 101, the rear beam 102, the left side beam 103 and the right side beam 104, which are close to the inner sides, are continuous surfaces without escape holes, so that the strength of the stress surface is ensured.

Example two

As shown in fig. 9-11, the present embodiment is a tooling structure for fixing winding end points of a reinforcement of an auxiliary frame, and the reinforcement of the auxiliary frame is also symmetrical, so that the tooling of the present embodiment is also symmetrical. The whole fixture is arranged on a base 6 so as to be convenient for integral movement, and the structures of four fixed connection brackets 3 are respectively arranged at four corners and correspond to the connection positions of four cross beams; the structure of the fixed metal bush 1 and the structure of the fixed connection bush 2 are connected together at positions corresponding to the left side member 103 and the right side member 104 to save parts and space; two structures for fixedly connecting the bushings 2 are separately provided at positions corresponding to the front beam 101.

As shown in fig. 12, the structure of the fixed connection bracket 3 includes a column one 611 and a slide rail one 613 fixed on the base 6, a cylinder one 614 is arranged on the column one 611, a support column one 612 is arranged on the slide rail one 613, a piston rod of the cylinder one 614 is connected with the support column one 612, the column one 611, the slide rail one 613, the support column one 612 and the cylinder one 614 enclose a square structure, an electromagnetic chuck 615 is arranged on the side surface of the support column one 612 facing the inner side of the tool, the cylinder one 614 pushes the electromagnetic chuck 615 to the installation position of the metal bushing 1 when pushing the support column one 612 to move along the slide rail one 613, and the electromagnetic chuck 615 is fixed or released by opening or closing a power switch 617 electrically connected with the coil inside the electromagnetic chuck 615.

As shown in fig. 13, in the structure of setting the structure of the fixed metal bush 1 and the structure of the fixed connection bush 2 together, the structure of the fixed metal bush 1 includes a column two 621 and a rail two 623 fixed on the base 6, a cylinder two 624 is provided on the column two 621, a support column two 622 is provided on the rail two 623, a piston rod of the cylinder two 624 is connected with the support column two 622, the column two 621, the rail two 623, the support column two 622 and the cylinder two 624 enclose a square structure, a fixed shaft two 626 is provided on a side of the support column two 622 facing the inner side of the tool, and when the cylinder two 624 pushes the support column two 622 to move forward, the fixed shaft two 626 is sent to the installation position of the metal bush 1. The structure of the fixed connection bushing 2 comprises a first sliding rail III 631 arranged on the base 6, a second sliding rail III 633 arranged on the side wall of the supporting column II 622, a first sliding rail III 631 and a second sliding rail III 633 which are vertical to each other, a cylinder III 632 is arranged on the first sliding rail III 631, a supporting column III 634 is arranged on the second sliding rail III 633, one end of the supporting column III 634 is arranged on the second sliding rail III 633, the other end of the supporting column III 634 is connected with a piston rod of the cylinder III 632, a fixing shaft III 635 is arranged on the side face of the supporting column III 634 facing the interior side of wages, the cylinder III 632 drives the supporting column III 634 to move up and down along the second sliding rail III 633 to adjust the position of the fixing shaft III 635, and then the position of the connection bushing 2 is adjusted, and the shape of the reinforcing body can be adjusted. And when the second cylinder 624 pushes the second support column 622 to move along the second slide rail 623, the third cylinder 632 is simultaneously driven by the third support column 634 to move along the third slide rail 631, and the third fixed shaft 635 is pushed to the installation position of the connecting bushing 2 by matching with the movement of the third cylinder 632.

As shown in fig. 14, for the structure of two sets of two metal bushings used for fixing the front beam 101 on the tool, each structure comprises a column four 641 and a slide rail four 642 which are fixed on the base 6, the column four 641 is provided with a cylinder four 644, the slide rail four 642 is provided with a support column four 643, the column four 641, the slide rail four 642, the support column four 643 and the cylinder four 644 enclose a square structure, the side surface of the support column four 643 facing one side inside the tool is provided with a fixing shaft five 645, and the cylinder four 644 pushes the support column four 643 to advance along the slide rail four 642 to push the fixing shaft four 645 to the installation position of the metal bushing 1.

The above embodiments are only for illustrating the present utility model, not for limiting the present utility model, and various changes and modifications may be made by one skilled in the relevant art without departing from the spirit and scope of the present utility model, so that all equivalent technical solutions shall fall within the scope of the present utility model, which is defined by the claims.

Claims (10)

1. A manufacturing method of an automobile light composite auxiliary frame is characterized by comprising the following steps: firstly, fixing a plurality of winding end points by using a tool, then winding continuous fibers (5) into an annular reinforcing body along the winding end points, forming a composite material on the reinforcing body to form an annular structure surrounded by a plurality of cross beams, and finally, pressing the cross beams into spherical hinges to form an auxiliary frame; and when in winding, the continuous fiber (5) is wound between two adjacent winding end points to form a sectional winding structure, and each sectional winding structure is connected into a whole through the winding end points.

2. The method for manufacturing the automobile lightweight composite subframe according to claim 1, wherein: the winding endpoint includes metal bush (1), connecting bush (2) and linking bridge (3), and metal bush (1) set up the position department of ball pivot on the sub vehicle frame, and connecting bush (2) set up the position department that is close to the centre in the sub vehicle frame crossbeam, and linking bridge (3) set up the position department of connecting at adjacent crossbeam.

3. The method for manufacturing the automobile lightweight composite subframe according to claim 1, wherein: the metal bushing (1) and the connecting bushing (2) are positioned by inserting the through holes of the metal bushing into the fixed shaft of the tool, and the connecting bracket (3) is adsorbed on the electromagnetic chuck (615) of the tool for positioning.

4. The method for manufacturing the automobile lightweight composite subframe according to claim 1, wherein: when the composite material is formed, a metal insert (4) is arranged in a forming die and is used as a structure for connecting the auxiliary frame with a vehicle.

5. The method for manufacturing the automobile lightweight composite subframe according to claim 1, wherein: the shape of the reinforcement is adjusted by adjusting the position of the connecting bush (2), thereby adjusting the appearance of the auxiliary frame.

6. The method for manufacturing the automobile lightweight composite subframe according to claim 1, wherein: the connecting support (3) is of a frame type three-dimensional structure formed by a plurality of edges, and continuous fibers (5) at different cross beams are wound on the connecting edges of the connecting support (3) in different directions.

7. The method for manufacturing the automobile lightweight composite subframe according to claim 1, wherein: the connecting support (3) is a frame structure formed by connecting two parallel triangular supports, and continuous fibers (5) at different cross beams are wound on connecting edges of the triangular supports in different directions.

8. The method for manufacturing the automobile lightweight composite subframe according to claim 1, wherein: continuous fibers (5) at the same cross beam are wound on the connecting edges of the two triangular supports in the same direction in a crossing manner.

9. The method for manufacturing the automobile lightweight composite subframe according to claim 1, wherein: the continuous fibers (5) are surface treated with a silane coupling agent prior to winding into a reinforcement.

10. The method for manufacturing the automobile lightweight composite subframe according to claim 1, wherein: the front beam (101) is provided with a 'rice' -shaped reinforcing rib structure on the surface facing the front.

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