FRAME
[001] The present subject matter generally relates to a frame. Particularly, the subject
matter relates to light weight cross-member shape chassis frame for heavy vehicle.
[002] Chassis Frame is the main load-bearing (or backbone) structure of heavy vehicle.
It is a main structure of the vehicle to bears bending and torsional loads due to the heavy cargo as well as it has to support the weight of all other systems like cabin, engine, driveline, loadbody, fuel tanks, battery box, bumper etc. are mounted on it. The Frame is suspended on axles through leaf springs which have been conventionally used in Indian market for many years. Chassis Frame should have adequate strength and stiffness to ensure its durability as well as mounting integrity of above systems. Conventional frame of a heavy-duty truck is a ladder structure made out of Steel having weight of approximate one ton. This arises a need for a light-weight frame with adequate structural durability so that customer can carry more pay-load for the same gross vehicle weight. Hence there is an unmet need of light weight cross-member shape chassis frame with adequate durability and stability to carry the pay load effectively.
[003] Although the subject matter is explained with the help of an example of underrun
protection device for vehicle, particularly heavy vehicle. The underrun protection device is light weight, cost effective system having a geometrical profile or shape, which may reduce the weight of the heavy vehicle, thereby increase the payload capacity of the heavy vehicle without compromising on the strength of the underrun. However, it shall become abundantly clear after reading this specification, that the subject matter may, without departing from the spirit and scope of the subject matter, also be applied to variation in embodiments related to front underrun, rear underrun and side underrun or other similar devices.
[004] The present subject matter meets the aforementioned and other needs by
providing a light-weight chassis frame having combination of steel and aluminum materials. The chassis frame is a unique modular cross-member shapes with a unique fastening methods.
[005] In another embodiment, the present subject matter provides a chassis frame of
heavy-duty truck which provides significant additional payload advantage (-200 Kg) for the

customer for same gross vehicle weight. Further the chassis frame is a long-members made up of steel so that it has adequate strength and stiffness in bending and the long-member stiffener is of Aluminum to save weight. Also the cross-members are also of Aluminum material optimized to provide adequate torsional strength and stiffness.
[006] In one embodiment, the x-shape cross-members are sub-assemblies of simple
extruded and formed aluminum sections connected by rivets which are simple to manufacture and assemble. The unique X-shape cross-members enable use of 5mm thick aluminum sections, which otherwise would have been 8-10mm thick heavier aluminum sections with conventional shapes. The X-shape cross-members are modular and can be increased in number for increase in wheel-base without disturbing the overall frame packaging and suspension mounting. The Frame is unique with first time use of Air Suspension for Trucks in India. For mounting of air suspension different X-shape cross-member are used with additional reinforcements to provide adequate local strength. All cross-member assemblies are done by single-side access steel rivets that are galvanized to prevent bi-metallic corrosion between aluminum and steel.
[007] The present subject matter relates to a frame system for a heavy vehicle frame
system that includes a composite cross-member. The composite cross member includes a first face sheet and second face sheet. A core material is positioned between the two face sheets. All the components of the composite cross-member are then bonded together.
[008] In one embodiment, each face sheet of the composite cross-member contains an
end flange to allow for mounting. The face sheets are secured to a cross diagonal "X" shaped member, which attaches the cross-member to the frame rail. The face sheets, core and "X" shaped member are all bonded together.
[009] In another embodiment, the face sheets are fastened to a mounting bracket. The
face sheets and core material form a center section, which is secured between two surfaces of the mounting bracket. The face sheets and core material are bonded together to form the center section. The mounting brackets are then secured to the frame rail. In one embodiment, the mounting brackets are castings.

[0010] In yet another embodiment of the present subject matter, a plurality of composite cross-members are positioned "X" shaped diagonal structure to the two frame rails to form a frame system for a heavy vehicles. A stiffening member may be attached to both frame rails over the span of two adjacent composite cross-members to provide extra stiffness in the frame when increased frame system rigidity is needed.
[0011] The new design has many advantages over the prior art design. The new design allows for better serviceability. Service shops can easily remove the cross-member. The new cross-member design can be removed by simply removing the cross-member from the mounting brackets and replacing a new cross-member. Easy removal of the new cross-member saves time and money when service is required.
[0012] With the disclosed design, a heavy vehicle frame can contain common cross-members. For example, from the second bend in the frame back, excluding the over the transmission cross-member and the rear closing cross-member can be the same. The face sheets of the new design contain flat surfaces on both sides of the cross-member for easier mounting of components such as brake lines, electrical wires and the like. The new cross-member will allow for dramatic weight reduction in the vehicle which in turn leads to lower operating cost of the vehicle. The lighter cross-member can improve a manufacturer's assembly efficiency.
[0013] In another embodiment, the present subject matter provides a method of manufacturing the light-weight chassis frame. More particularly, the light weight cross-member shape chassis frame for heavy vehicle.
[0014] The subject matter shall now be described with reference to accompanying figures, wherein:
[0015] FIG.l shows a schematic diagrams of alight weight cross member shaped chassis frame illustrating the connection of the cross-member to the frame rail;

[0016] FIG.2 shows the perspective view of one embodiment of a composite cross-member of the present subject matter;
[0017] FIG. 3 shows a exploded view of one embodiment of the composite cross-member of FIG. 1 in accordance with the present subject matter;
[0018] FIG. 4 shows another exploded view of one embodiment of the composite cross-member of FIG. 1 in accordance with the present subject matter.
[0019] Before the present subject matter is described in further detail, it is to be understood that the subject matter is not limited to the particular embodiments described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims. It must be noted that as used herein and in the appended claims, the singular forms "a", "an" and "the" include plural referents unless the context clearly dictates otherwise.
[0020] FIG. 1 shows a schematic diagrams of a light weight cross member shaped chassis frame illustrating the connection of the cross-member to the frame rail 100 comprises side member assemblies and cross member assemblies.
[0021] The side member assembly consists of a long member, stiffeners and welded hardware. The long member section can be categorized into two major surfaces: the web and the flange. The web is the portion that is aligned to the sides of the assembly at which all major components are bolted to the frame. The web is responsible for transferring maximum load of the vehicle to axles. Flanges are dimensionally smaller than web, but act as a mounting surface for critical components like suspension brackets. Flanges also resists to deformation of the twisting frame during turning. The cross member assembly consists of gussets and cross members along with any additional components such as legs or Cross member stiffeners. The cross member is

responsible for the transfer of the load from LH to RH chassis side member assembly. It also provides stiffness to frame for lateral, torsional and vertical loads.
[0022] FIG. 2 shows perspective view of one embodiment of a composite cross-member of the present subject matter as illustrated by number 200. It is apparent from the FIG.2 that the cross-members are positioned "X" shaped diagonal structure to the two frame rails to form a frame system for a heavy vehicles. A stiffening member may be attached to both frame rails over the span of two adjacent composite cross-members to provide extra stiffness in the frame when increased frame system rigidity is needed.
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[0023] The new design has many advantages over the current design. The new design allows for better serviceability. Service shops can easily remove the cross-member. The new cross-member design can be removed by simply removing the cross-member from the mounting brackets and replacing a new cross-member. Easy removal of the new cross-member saves time and money when service is required.
[0024] FIG. 3 shows an exploded view of one embodiment of the composite cross-member 300 of the present subject matter. The exploded view of composite cross-member 300. The top and bottom of the two gussets of the composite cross member is riveted in the horizontal orientation. The gussets are bolted to the Web of the frame. Similarly, in the rear, the two C sections are riveted in the vertical orientation as shown in FIG.3. Longer gusset is required in rear cross member because rear axle reaction is greater than front axle reaction. Longer gussets distribute the load over a longer span of side member. Further the cross members were placed to support the point loads from left to right on the frame side member.
[0025] FIG. 4 shows another exploded view of one embodiment of the composite cross-member of FIG. 1 in accordance with the present subject matter. The exploded view of composite cross-member 400. The top and bottom of the two gussets of the composite cross member is riveted in the parallel orientation to each other. The gussets are bolted to the Web of the frame as illustrated in FIG. 3

The foregoing descriptions of specific embodiments of the present subject matter have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present subject to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present subject matter and its practical application, to thereby enable others skilled in the art to best utilize the present subject matter and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the spirit or scope of the present subject matter.

We claim:
1. A light weight frame for heavy vehicle comprises first and second modular cross-member wherein the frame comprises a composite material made up of steel and aluminum.
2. The cross-member of claim 1, wherein said frame is constructed from composite material made up of aluminum and steel.
3. The cross-member of claim 1, wherein said first and second cross-member modular sheets are arranged diagonally.
4. The cross-member modular sheet of claim 1 further comprising unique mountings attached to said first and second face sheets and said core material sheet to mount the cross member to the frame rails.