DESC:FIELD
The present disclosure relates to the field of vehicle frame structures.
BACKGROUND
The background information herein below relates to the disclosure but is not necessarily prior art.
Conventionally two-wheeler frames are integral to the vehicle's structural integrity, directly impacting performance, safety, and longevity. Traditionally, many two-wheelers utilize welded frames, where metal components are permanently fused through welding processes. Despite their widespread use, welded frames present several significant drawbacks that can limit their effectiveness and durability.
A primary concern with welded frames is the reduction in strength caused by the Heat Affected Zone (HAZ) inherent in the welding process. The intense heat applied during welding alters the material's microstructure around the joints, resulting in decreased mechanical properties such as strength and fatigue resistance. This weakening effect can compromise the frame's ability to withstand the dynamic loads and stresses experienced during two-wheeler operation.
Moreover, maintaining consistent quality in welded frames is challenging due to common weld issues. These include weld distortion, improper weld penetration, and other defects that can affect the frame's alignment and dimensional accuracy. Such defects not only impair the frame's performance but also necessitate additional inspection and rework, increasing production costs and time.
Another limitation of welded frames is the lack of flexibility in repair and maintenance. In the event of an accident or damage, the entire chassis may need to be replaced, as individual parts cannot be easily changed or repaired. This inflexibility can lead to higher repair costs and longer downtimes, impacting the overall lifecycle cost of the two-wheeler.
Thus, there is felt a need for a bolted frame assembly for two-wheeler, which alleviates the aforementioned drawbacks.
OBJECTS
Some of the objects of the disclosure, which at least one embodiment herein satisfies, are as follows:
It is an object of the disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
An object of the disclosure is to provide a bolted frame assembly for two-wheelers.
Another object of the present disclosure is to provide a bolted frame assembly that provides a frame structure that enables quick and easy assembly using bolted connections, reducing the need for specialized tools and welding expertise.
Yet another object of the disclosure is to provide a bolted frame assembly that reduces the occurrence of weld-related defects, such as distortion and improper penetration, ensuring consistent quality and reliability.
Still yet another object of the disclosure is to provide a bolted frame assembly that is modular.
Another object of the present disclosure is to provide a bolted frame assembly that allows for easy customization and adaptability.
Yet another object of the disclosure is to provide a bolted frame assembly that facilitates interchangeability of the components to reduces cost.
Still yet another object of the present disclosure is to provide a bolted frame assembly that facilitates straightforward maintenance and repair by allowing easy disassembly of components, reducing downtime and associated repair costs.
Another object of the present disclosure is to provide a bolted frame assembly that enhances durability and longevity, capable of withstanding the dynamic loads and stresses encountered during normal and extreme riding conditions.
Yet another object of the disclosure is to provide a bolted frame assembly that is modular.
Still yet another object of the present disclosure is to provide a bolted frame assembly that optimizes material use and minimizes waste, contributing to more sustainable and environmentally friendly manufacturing practices.
Other objects and advantages of the disclosure will be more apparent from the following description, which is not intended to limit the scope of the disclosure.
SUMMARY
In accordance with one aspect, this disclosure provides a bolted frame assembly for a two-wheeler, comprising: an operative left side frame structure, an operative right side frame structure, a head stock, a cross member, a top tube, a bottom tube, bolts or pins, a swing arm pivot brackets, a suspension mounting bracket, at least one spacer, at least one forged part.
The operative left side frame structure and the operative right side frame structure, each including a top tube and a bottom tube.
The head stock is positioned at the front of the frame and connected to the operative right side top tube the operative left-hand top tube, the operative right-hand bottom tube, and the operative left side bottom tube via bolts or pins, enabling secure attachment and modularity.
The cross member extends between the operative left side and the operative right side frame structures, providing lateral stability and rigidity, wherein the cross member is secured to the top and bottom tubes through forged parts and the bolts/pins.
The swing arm pivot assembly is operatively connected between the operative left side and the operative right side frame structures, secured by swing arm pivot brackets using the bolts or pins and supported by fixtures for added stability.
The suspension mounting bracket is attached to the operative left side and the operative right side frame structures using the bolts/pins, providing an attachment point for rear suspension components.
The spacer is integrated into the operative left side and the operative right side frame structures to maintain alignment and spacing between components, configured to absorb compressive stress during tightening.
The forged part is positioned at critical connection points for reinforcement, improving the durability and structural integrity of the bolted frame assembly.
In an embodiment, wherein the head stock is connected to the top tubes and the bottom tubes through the forged part welded to the tubes, with one bolt acting as a dowel for alignment and the other bolt providing clearance to facilitate easy assembly.
In an embodiment, wherein the cross member comprises a rectangular, square, or circular pipe with forged parts at its ends, configured to be interchangeable across different regions of the frame by modifying the machining area.
In an embodiment, the swing arm pivot is secured to the operative left side and operative right side frame structures through dowels and bolts/pins at both the top and bottom tubes, allowing for vertical movement and connection to the rear suspension swing arm.
In an embodiment, the suspension mounting bracket is a forged part that is configured for quick attachment and detachment, secured by bolts/pins and aligned by spring dowels, allowing for easy maintenance and customization of suspension settings.
In an embodiment, at least one locator is integrated into the forged parts to ensure precise alignment during assembly, preventing unwanted rotation and misalignment of frame components.
In an embodiment, the forged parts are made from high-strength alloy steel to improve durability and resistance to impact, ensuring the frame assembly can withstand dynamic loads during operation.
In an embodiment, wherein the tubular elements are constructed from aluminium alloy, providing a lightweight yet strong frame, reinforced at the junctions with forged components to further enhance strength and rigidity.
In accordance with another aspect, this disclosure provides a method for assembling a bolted frame assembly for a two-wheeler, the method comprising:
o aligning an operative left side top tube and an operative right side top tube with a head stock , and aligning an operative left side bottom tube and an operative right side bottom tube with the head stock, ensuring accurate positioning and alignment of the tubes relative to the head stock.
o securing the top tubes and bottom tubes to the head stock using bolts or pins through pre-aligned holes in forged parts, wherein one bolt/pin acts as a dowel for alignment, and the other provides clearance, facilitating proper assembly;
o fastening at least one cross member between the operative left side and operative right side frame structures, the cross member being secured to the top tubes and bottom tubes using bolts or pins through forged parts, providing lateral stability to the frame assembly.
o installing a swing arm pivot between the operative left side and operative right side frame structures, securing the swing arm pivot brackets to the bottom tubes using bolts or pins and spring dowels, ensuring proper attachment of the rear suspension system.
o attaching a suspension mounting bracket to the operative left side and operative right side frame structures using bolts or pins, aligning the suspension mounting bracket with dowels to securely support the rear suspension components;
o inserting at least one spacer is welded to the top tubes 204A, 204B and bottom tubes 206A,206B between the operative left side and operative right side frame structures at designated junctions, wherein the spacer absorbs compressive stress when the bolts or pins are tightened, maintaining the alignment and spacing of the frame component;
o tightening all bolts or pins securing the head stock, cross member, swing arm pivot brackets, and suspension mounting bracket, ensuring a rigid and stable assembly; and
o conducting a final quality check, verifying that the locators integrated into the forged parts have ensured precise positioning and alignment of all components, preventing unwanted movement or misalignment, and confirming that all bolts or pins are properly torqued.
In an embodiment, the method includes the top tubes, and the bottom tubes are constructed from aluminium alloy, and method further comprises reinforcing the junctions of the tubes with the forged parts to improve the structural strength of the assembly.
In an embodiment, the method further comprises installing an anti-rotation feature using embosses located on the forged parts, which prevent the rotation of components during assembly and operation, enhancing the precision of the assembly.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A bolted frame assembly for a two-wheeler, of the present disclosure, will now be described with the help of the accompanying drawing, in which:
FIGURE 1 illustrates an isometric view of a welded frame assembly of prior art;
FIGURE 2 illustrates an exploded view of a bolted frame assembly in accordance with the present disclosure;
FIGURE 3A illustrates a view of a cross member section of Figure 2;
FIGURE 3B illustrates a cross-section view of figure 3A along the Z-axis direction;
FIGURE 3C illustrates a cross-section view of figure 3A along the X-axis direction;
FIGURE 4A illustrates a left-side view of a rear suspension mounting part section of figure 2;
FIGURE 4B illustrates a cross-section view of section C-C of Figure 4A;
FIGURE 4C illustrates a cross-section view of section D-D of Figure 4A;
FIGURE 5A illustrates an isometric view of a swing arm pivot part section of figure 2;
FIGURE 5B illustrates a left-side view of a swing arm pivot part section of figure 5A;
FIGURE 5C illustrates a cross-section view of section E-E of Figure 5B;
FIGURE 5D illustrates a cross-section view of section F-F of Figure 5B;
FIGURE 5E illustrates a cross-section view of section G-G of Figure 5B
FIGURE 5F illustrates a cross-section view of section H-H of Figure 5B
FIGURE 6A illustrates a left-side view of a head stock part section of Figure 2;
FIGURE 6B illustrates a cross-section view of section J-J of Figure 6A; and
Figure 7A and 7B illustrates a flow chart of method for assembly of a bolted frame assembly in accordance with the present disclosure.
LIST OF REFERENCE NUMERALS
100 welded frame assembly of prior art
102 head stock of prior art
104A right hand (RH) side top tube of prior art
104B left hand (LH) side top tube of prior art
106A right hand (RH) side bottom tube of prior art
106B left hand (LH) side bottom tube of prior art
108 cross member of prior art
110 swing arm pivot of prior art
111A right hand (RH) side swing arm pivot bracket of prior art
111B left hand (LH) side swing arm pivot bracket of prior art
112 suspension mounting bracket of prior art
200 Bolted Frame Assembly of The Present Disclosure
202 Head Stock
204A Right Hand (RH) Side Top Tube
204A Left Hand (LH) Side Top Tube
206B Right Hand (RH) Side Bottom Tube
206B Left Hand (LH) Side Bottom Tube
208 Cross Member
210 Swing Arm Pivot
211A Right Hand (Rh) Side Swing Arm Pivot Bracket
211B Left Hand (LH) Side Swing Arm Pivot Bracket
212 Suspension Mounting Bracket
214 Spacer
215 Forged Part
218 Locator
228 Dowel
235 Bolts/Pins
300-316 Method and method steps
DETAILED DESCRIPTION
The present disclosure relates to the field of vehicle frame structures, and more particularly to a modular bolted frame assembly for two-wheelers that enhances structural integrity, ease of assembly, maintenance, and repair by employing bolted connections instead of traditional welded joints.
Embodiments, of the disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the disclosure. As used in the disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, elements, components, and/or groups thereof.
When an element is referred to as being "mounted on," “engaged to,” "connected to," or "coupled to" another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
A welded frame assembly 100 of the prior art will now be described with reference to Figure 1. Figure 1 illustrates an isometric view of the welded frame assembly 100 of prior art and describes the traditional two-wheeler frame 100 design where pipes and sheet metal parts are joined using welding.
The welded frame assembly of the prior art 100 comprises several key components connected through welding to create a motorcycle frame. A head stock 102 welded to the right side(RH) side top tube 104A and the left side(LH) side top tube 104B. These top tubes extend from the head stock 102 towards the rear of the frame and are welded at various junctions, including their connections to the head stock 102 and the cross member 108. The right side(RH) side bottom tube 106A and the left side(LH) side bottom tube 106B are welded to the head stock 102 at the front and to the cross member 108 at the rear. The cross member 108 is a horizontal element welded between the top tubes 104A, 104B and the bottom tubes 106A, 106B. A swing arm pivot 110 connects the rear suspension swing arm to the frame and is welded to the swing arm pivot brackets 111A, 111B. These brackets are welded to the frame to provide support for the swing arm pivot 110. Additionally, the suspension mounting bracket 112 is welded to the frame to secure the rear suspension components.
This welded frame assembly 100 as illustrated in Figure 1 is formed using a welding process that creates a heat affected zone around the welds, which can weaken the material and reduce the overall strength of the frame. This reduction in strength can compromise the structural integrity of the motorcycle, particularly under high-stress conditions. Ensuring consistent quality in welded frames is difficult due to potential issues like weld distortion, improper weld penetration, and other defects. These issues can affect the alignment and dimensional accuracy of the frame, leading to performance degradation. Further, In the event of an accident or damage, the welded frame typically requires complete replacement of the chassis, as individual parts cannot be easily changed or repaired. This results in higher repair costs and longer downtimes.
Therefore, there is a need for a modular bolted frame assembly 200 for two-wheelers that alleviates the aforementioned drawbacks.
A bolted frame assembly 200 for two-wheelers of the present disclosure will now be described with reference to Figure 2 to Figure 7. The preferred embodiment does not limit the scope and ambit of the present disclosure.
Figure 2 illustrates an exploded view of a bolted frame assembly in accordance with the present disclosure and describes the proposed bolted frame assembly 200 is shown.
The bolted frame assembly 200 for two-wheelers includes a left side(LH) frame structure and a right side(RH) frame structure, each of which includes a top tube and a bottom tube. Specifically, the (LH) frame structure consists of a top tube 204B and a bottom tube 206B, while the (RH) frame structure consists of a top tube 204A and a bottom tube 206A. These (RH) frame structure 204A, 206A and (LH) frame structure 204B, 206B are interconnected at the front by a head stock 202 and at the rear by swing arm pivot brackets 211A and 211B.
As shown in Figure 2 and Figures 6A and 6C, the head stock 202 serves as the pivotal connection point for the front fork and handlebars. It is securely attached to the frame by bolts/pins 235. The right side top tube 204A and the left side top tube 204B extend from the head stock towards the rear of frame 200. These top tubes 204A, 204B are connected to the head stock 202 and a cross member 208 via bolts/pins 235, providing upper structural support. Similarly, the right side bottom tube 206A and the left side bottom tube 206B form the lower section of the frame 200. These bottom tubes are also bolted to the head stock 202 and cross member 208, facilitating easy assembly and modification.
Figure 6A illustrates a left-side view of a head stock part section of Figure 2; and Figure 6B illustrates a cross-section view of section J-J of Figure 6A. Figures 6A-6B describes the head stock 202 bolted to the top tube 204A, 204B and bottom tubes 206A, 206B through a forged part 215 that is welded to the tubes. One bolt 235 acts as a dowel to assist in locating the head stock 102 during assembly, while the other bolt 235 has clearance with the hole in the forged part that is welded to the tubes.
Figure 3a illustrates a view of a cross member section of figure 2; Figure 3b illustrates a cross-section view of figure 3a along the z-axis direction; and Figure 3c illustrates a cross-section view of figure 3a along the x-axis direction.
The cross member 208 is a horizontal component that is configured to be is bolted to both the top tubes 204A, 204B and bottom tubes 206A, 206B and configured links the left and right sides of the frame 200. It thereby ensuring lateral stability and rigidity. As illustrated in Figures 3A to 3C, the cross member is constructed with two forged parts 215 at its ends. The forged parts 215 are configured for universal use across different areas of the frame 200, with modifications only in the machining area to match the tubes. This configuration allows for efficient manufacturing and assembly. Additionally, the cross member 208 provides provisions for mounting accessories such as batteries, as depicted in Figure 3.
In an embodiment, the cross-members can be a rectangular pipe, a square pipe, circular pipe or the like.
Figure 4A illustrates a left-side view of a rear suspension mounting part section of figure 2; Figure 4B illustrates a cross-section view of section C-C of Figure 4A; and Figure 4C illustrates a cross-section view of section D-D of Figure 4A;
Figure 5A illustrates an isometric view of a swing arm pivot part section of figure 2; Figure 5B illustrates a left-side view of a swing arm pivot part section of figure 5A; Figure 5C illustrates a cross-section view of section E-E of Figure 5A; Figure 5D illustrates a cross-section view of section F-F of Figure 5A; Figure 5E illustrates a cross-section view of section G-G of Figure 5A; and Figure 5F illustrates a cross-section view of section H-H of Figure 5A;
A swing arm pivot 210 is configured to connect the rear suspension swing arm (not shown) to the frame 200, allowing for vertical movement. The swing arm pivot 210 is configured to be supported by improved swing arm pivot brackets 211A and 211B, as shown in Figures 4A to 5F. These brackets are bolted to the frame using bolts/pins 235 and Dowel pin 228, providing secure and adjustable mounting points for the swing arm pivot.
In an embodiment, the swing arm pivot 210 forged part may assemble first with a dowel 228 at the top tube 204A, 204B and the bottom tube 206A, 206B, and two bolts 235 are used to connect the forged part to the top tube 204A, 204B and bottom tube 206A, 206B.
A suspension mounting bracket 212 is configured to be fixed to the frame 200, offering a stable attachment point for the rear suspension components. This bracket ensures that the suspension system is securely anchored while permitting easy adjustments.
A spacer 214, illustrated in Figure 4B, maintains proper alignment and spacing between frame 200 components. At least one of the tubes 204A, 204B, 206A, 206B includes a spacer 114 welded to it from the outside. The spacer 114 is configured to take compressive stress when tightened by bolts 235.
Forged parts 215 are employed in areas requiring additional strength. These components are integrated into the frame using bolted connections, enhancing the frame's durability. Locators 218 are used to ensure precise positioning of frame components during assembly, which is essential for maintaining consistent quality.
In an embodiment, the forged end parts 215 of the cross members 108 may include an emboss that acts as the locator 218 and prevents rotation during assembly.
The spring dowel 228 adds security and alignment for critical connections, ensuring that components remain firmly in place under dynamic loads. Bolts/pins 235 and fixtures 245 are integral to the assembly, providing the necessary strength and flexibility for secure connections and ease of maintenance.
In an embodiment, the suspension mounting bracket 212 is designed for quick attachment and detachment,
In an embodiment, the rear suspension mounting bracket 212 may be a forged part with threading and may be configured to be assembled first with a spring dowel 228.
In an embodiment, forged parts 215 are utilized in critical areas of the frame to provide additional strength and durability, enhancing overall resilience.
In an embodiment, the head stock 202 part may be bolted to the top tubes 204A, 204B and bottom tubes 206A, 206B through a forged part 215 that may be welded to the tubes, but not limited to wherein: one bolt 235 acts as a dowel to help in locating the head stock 202 during assembly, and the other bolt 235 has clearance with the hole in the forged part 215 welded to the tubes.
In an embodiment, the forged components may be made from high-strength alloy steel to improve durability and impact resistance.
In an embodiment, the tubular elements 204A, 204B, 206A, 206B may be constructed from aluminium alloy to reduce the overall weight of the frame while maintaining structural integrity.
In an embodiment, the cross members 108 may be configured with integrated channels for routing wiring or fluid lines, facilitating a streamlined assembly and maintenance process.
In an embodiment, the head stock 202 may include integrated mounting points for steering mechanisms, with the mounting points aligned to optimize handling and stability.
In an embodiment, the rear suspension mounting 212 may include adjustable components to allow for customization of suspension settings based on different riding conditions or user preferences.
In an embodiment, the swing arm pivot 210 may include a replaceable bearing assembly to facilitate maintenance and replacement of worn components.
In an embodiment, the forged components 215 and cross members 108 may be pre-machined to ensure precise fit and reduce assembly time.
In an embodiment, the tubular elements 204A, 204B, 206A, 206B may include internal reinforcements at junctions with the forged components to further enhance strength and rigidity.
In an embodiment, the assembly process may include a locking mechanism for the bolts 235 that prevents accidental loosening during operation.
In an embodiment, the frame 200 may be designed to accommodate aftermarket modifications by including standardized mounting points for additional accessories or components.
In an embodiment, the design of the head stock 202 may allow for adjustable steering geometry to accommodate different handling characteristics and rider preferences.
Figure 7A and 7B illustrates a flowchart that includes the steps involved in a method 300 for assembly modular bolted frame for two-wheelers, in accordance with an embodiment of the present disclosure.
The method 300 comprises the following steps:
At step 302, the method 300, includes aligning an operative left side top tube 204B and an operative right side top tube 204A with a head stock 202, and aligning an operative left side bottom tube 206B and an operative right side bottom tube 206A with the head stock 202, ensuring accurate positioning and alignment of the tubes relative to the head stock 202.
At step 304, the method 300, includes securing the top tubes 204A, 204B and bottom tubes 206A,206B to the head stock 202 using bolts or pins 235 through pre-aligned holes in forged parts 215, wherein one bolt/pin 235 acts as a dowel 228 for alignment, and the other provides clearance, facilitating proper assembly.
At step 306, the method 300, includes fastening at least one cross member 208 between the operative left side and operative right side frame structures, the cross member 208 being secured to the top tubes 204A,204B and bottom tubes 206A,206B using bolts or pins 235 through forged parts 215, providing lateral stability to the frame assembly.
At step 308, the method 300, includes installing a swing arm pivot 210 between the operative left side and operative right side frame structures, securing the swing arm pivot brackets 211A,211B to the bottom tubes 206A,206B using bolts or pins 235 and dowels 228, ensuring proper attachment of the rear suspension system.
At step 310, the method 300, includes attaching a suspension mounting bracket 212 to the operative left side and operative right side frame structures using bolts or pins, aligning the suspension mounting bracket 212 with dowels 228 to securely support the rear suspension components.
At step 312, the method 300, includes inserting at least one spacer 214 welded in the top tubes 204A, 204B and bottom tubes 206A,206B between the operative left side and operative right side frame structures at designated junctions, wherein the spacer absorbs compressive stress when the bolts or pins 235 are tightened, maintaining the alignment and spacing of the frame component.
At step 314, the method 300, includes tightening all bolts or pins 235 securing the head stock 202, cross member 208, swing arm pivot brackets 211A, 211B, and suspension mounting bracket 212, ensuring a rigid and stable assembly.
At step 316, the method 300, includes conducting a final quality check, verifying that the locators 218 integrated into the forged parts 215 have ensured precise positioning and alignment of all components, prevented unwanted movement or misalignment, and confirmed that all bolts or pins 235 are properly torqued.
In an operative configuration, the bolted frame assembly includes an operative left side frame structure and an operative right side frame structure, each comprising a top tube 204A,204B and a bottom tube 206A,206B. These tubes are securely attached to the head stock 202 using bolts or pins 235, with forged parts 215 welded to the tubes to facilitate easy alignment and attachment. The cross member 208 is bolted between the left and right frame structures, providing lateral stability. The swing arm pivot 210 assembly is securely attached using swing arm pivot brackets 211A, and 211B, and the rear suspension mounting bracket 212 is bolted to the frame, ensuring robust support for the suspension system. Spacers 214 are strategically placed to maintain alignment and absorb compressive stress during tightening, ensuring a secure and rigid structure. Locators 218 and dowels 228 are integrated to prevent unwanted movement and ensure proper alignment of all components, enhancing the overall structural integrity and ease of assembly.
Advantageously, the bolted frame assembly offers several key benefits over traditional welded frames. The modular design allows for easy assembly, disassembly, and repair, significantly reducing maintenance time and costs. By eliminating the need for welding, the assembly avoids the common issues associated with heat-affected zones, such as reduced material strength and weld distortions. The use of bolts and spacers provides consistent alignment and minimizes the risk of misalignment during assembly. Additionally, the forged parts and high-strength materials enhance the overall durability and resilience of the frame, making it capable of withstanding dynamic loads and extreme riding conditions. This configuration also allows for greater customization, enabling users to modify or replace individual components as needed without the need for extensive rework or specialized tools.
The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are considered to be within the scope of the disclosure.
TECHNICAL ADVANCEMENTS AND ECONOMICAL SIGNIFICANCE
The present disclosure described hereinabove has several technical advantages including, but not limited to, a frame assembly for two-wheelers which;
? enhances structural integrity by providing a motorcycle frame that maintains high strength and structural integrity without the weaknesses associated with the heat affected zone (HAZ) caused by welding.
? improves quality control by reducing the occurrence of weld-related defects, such as distortion and improper penetration, ensuring consistent quality and reliability.
? has a modular frame design that allows for easy replacement and repair of individual components, minimizing the need for complete chassis replacement in the event of damage or an accident.
? provides cost-effective maintenance that reduces the overall lifecycle cost of the motorcycle by facilitating easier and more cost-effective maintenance and repair processes, thus decreasing downtime and repair expenses.
? increases design flexibility that offers greater flexibility in design and assembly, allowing for customization and adaptation to different motorcycle models and configurations.
? increases durability by exhibiting enhanced durability and longevity, capable of withstanding the dynamic loads and stresses encountered during normal and extreme riding conditions.
? provides sustainable manufacturing to develop a frame construction method that optimizes material use and minimizes waste, contributing to more sustainable and environmentally friendly manufacturing practices.
The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, or group of elements, but not the exclusion of any other element, or group of elements.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. ,CLAIMS:WE CLAIM:
1. A bolted frame assembly (200) for two-wheeler, comprising:
? an operative left side frame structure and an operative right side frame structure, each including a top tube (204A, 204B) and a bottom tube (206A, 206B);
? a head stock (202) positioned at the front of the frame and connected to said operative right side top tube (204A) said operative left side top tube (204B), said operative right side bottom tube (206A), and said operative left side bottom tube (206B) via bolts or pins (235), enabling secure attachment and modularity;
? a cross member (208) extending between said operative left side and said operative right side frame structures, providing lateral stability and rigidity, wherein the cross member is secured to the top and bottom tubes through forged parts (215) and said bolts/pins (235);
? a swing arm pivot assembly (210) operatively connected between said operative left side and said operative right side frame structures, secured by swing arm pivot brackets (211A, 211B) using said bolts or pins (235) and for added stability;
? a suspension mounting bracket (212) attached to said operative left side and said operative right side frame structures using said bolts/pins (235), providing an attachment point for rear suspension components;
? at least one spacer (214) integrated into said operative left side and said operative right side frame structures to maintain alignment and spacing between components, configured to absorb compressive stress during tightening; and
? at least one forged part (215) positioned at critical connection points for reinforcement, improving the durability and structural integrity of the bolted frame assembly.
2. The bolted frame assembly (200) as claimed in claim 1, wherein said head stock (202) is connected to said top tubes (204A, 204B) and said bottom tubes (206A, 206B) through said forged part (215) welded to the tubes, with one bolt (235) acting as a dowel for alignment and the other bolt providing clearance to facilitate easy assembly.
3. The bolted frame assembly (200) as claimed in claim 1, wherein said cross member (208) comprises a rectangular, square, or circular pipe with forged parts (215) at its ends, configured to be interchangeable across different regions of the frame by modifying the machining area.
4. The bolted frame assembly (200) as claimed in claim 1, wherein said swing arm pivot (210) is secured to the operative left side and operative right side frame structures through dowels (228) and bolts/pins (235) at both the top and bottom tubes, allowing for vertical movement and connection to the rear suspension swing arm.
5. The bolted frame assembly (200) as claimed in claim 1, wherein said suspension mounting bracket (212) is a forged part that is designed for quick attachment and detachment, secured by said bolts/pins (235) and aligned by dowels (228), allowing for easy maintenance and customization of suspension settings.
6. The bolted frame assembly (200) as claimed in claim 1, wherein at least one locator (218) is integrated into the forged parts (215) to ensure precise alignment during assembly, preventing unwanted rotation and misalignment of frame components.
7. 7. The bolted frame assembly (200) as claimed in claim 1, wherein said forged parts (215) are made from high-strength alloy steel to improve durability and resistance to impact, ensuring the frame assembly can withstand dynamic loads during operation.
8. The bolted frame assembly (200) as claimed in claim 1, wherein the tubular elements (204A, 204B, 206A, 206B) are constructed from aluminium alloy, providing a lightweight yet strong frame, reinforced at the junctions with forged components to further enhance strength and rigidity.
9. A method (300) for assembling a bolted frame assembly (200) for two-wheeler, the method comprising:
o aligning an operative left side top tube (204B) and an operative right side top tube (204A) with a head stock (202), and aligning an operative left side bottom tube (206B) and an operative right side bottom tube (206A) with the head stock (202), ensuring accurate positioning and alignment of the tubes relative to the head stock;
o securing the top tubes (204A, 204B) and bottom tubes (206A, 206B) to the head stock (202) using bolts or pins (235) through pre-aligned holes in forged parts (215), wherein one bolt/pin (235) acts as a dowel for alignment, and the other provides clearance, facilitating proper assembly;
o fastening at least one cross member (208) between the operative left side and operative right side frame structures, the cross member being secured to the top tubes (204A, 204B) and bottom tubes (206A, 206B) using bolts or pins (235) through forged parts (215), providing lateral stability to the frame assembly;
o installing a swing arm pivot (210) between the operative left side and operative right side frame structures, securing the swing arm pivot brackets (211A, 211B) to the bottom tubes (206A, 206B) using bolts or pins (235) and dowels (228), ensuring proper attachment of the rear suspension system;
o attaching a suspension mounting bracket (212) to the operative left side and operative right side frame structures using bolts or pins (235), aligning the suspension mounting bracket with dowels (228) to securely support the rear suspension components;
o inserting at least one spacer (214) spacer 214 welded in the top tubes 204A, 204B and bottom tubes 206A,206B between the operative left side and operative right side frame structures at designated junctions, wherein the spacer absorbs compressive stress when the bolts or pins (235) are tightened, maintaining the alignment and spacing of the frame component;
o tightening all bolts or pins (235) securing the head stock (202), cross member (208), swing arm pivot brackets (211A, 211B), and suspension mounting bracket (212), ensuring a rigid and stable assembly,
o conducting a final quality check, verifying that the locators (218) integrated into the forged parts (215) have ensured precise positioning and alignment of all components, preventing unwanted movement or misalignment, and confirming that all bolts or pins (235) are properly torqued.
10. The method (300) as claimed in claim 11, wherein said top tubes (204A, 204B) and said bottom tubes (206A, 206B) are constructed from aluminium alloy, and said method (300) further comprises reinforcing the junctions of the tubes with the forged parts (215) to improve the structural strength of the assembly.
11. The method (300) as claimed in claim 11, further comprises: installing an anti-rotation feature using embosses located on the forged parts (215), which prevent the rotation of components during assembly and operation, enhancing the precision of the assembly.

Dated this 29th Day of November, 2024

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
OF R. K. DEWAN & CO.
AUTHORIZED AGENT OF APPLICANT

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT CHENNAI