F2010F014
Concept of a Lightweight Heavy Truck Frame for Increased Transportation Efficiency
The increasing demands on the transportation efficiency present new challenges to the vehicle architecture. Optimization of the internal combustion engine as the dominant power source in order to achieve the EURO6 emission requirements, or newly propulsion systems as CNG or hybrid drives are only one approach to meet the future transport challenge also regarding emissions. Along with these alternative propulsion systems is a significant increase of vehicle curb weight is expected, which reduces the potential payload [1].
The described new concept offers, by substitution of the conventional ladder frame by a "monocoque frame" with welded sheet metal parts, a significant weight reduction of the vehicle chassis. The new structure, which consists of several modules, presents new vehicle architecture by e.g. relocation of the fuel tanks towards the vehicle centre. Another major advantage of the monocoque frame is an approved dynamics. Through its revolutionary design, the structure has a much higher stiffness which has a positive effect on driving dynamics.
The structure consists of a frame head module, a front axle module, a middle section and a rear axle module. By variation of the length of the middle module, a wheelbase modification can be realized easily. Apart from the casted frame head module, all modules are bent or pressed steel sheet metals. The parts will be welded to the respective modules. Front axle-, middle- and rear axle module will be welded to a complete frame assembly. Due to assembly and repair reasons, the frame head module is bolted.
The monocoque frame has been optimized using FEM analyses. Besides the classical stress calculations, stiffness and natural frequency analysis and durability analyses have been performed. Particular attention in the durability analyses was paid on the assessment of welded connections [2, 3].
The new commercial vehicle frame structure offers, compared to a conventional ladder frame, a significant weight reduction (~30%). Through the use of steel compared to alternative materials, such as aluminium or CFK, substantial benefits in terms of corrosion, acoustics, manufacturing and specially costs can be generated.
This abstract is supplemented by a PDF, which can be viewed here.
Poster presentation: Buses, trucks and heavy vehicles