Adjustable Reinforcing Member for EV Battery Mounting
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Solution Overview
Problem
The existing battery unit mounting structures for electric vehicles require multiple types of reinforcing members due to varying cross-sectional shapes of side members, leading to increased manufacturing costs and complexity in management.
Innovation Solution
A battery unit mounting structure that includes a beam member between side members, cylindrical nut members, and adjustable reinforcing members with a first and second plate portion, allowing for standardized components that can be adjusted to fit different cross-sectional distances between side member walls, thereby enhancing the strength of the mounting portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple types of reinforcing members are used to match varying cross-sectional shapes of side members, then the strength of battery unit mounting portions is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The reinforcing member is designed with a universal structure that can be used across multiple mounting positions despite variations in side member cross-sectional shapes. The L-shaped configuration with adjustable flange orientations allows a single reinforcing member type to serve multiple functions in different locations, eliminating the need for multiple specialized types while maintaining structural strength requirements.
Solution Approach 2:
The reinforcing member design incorporates variable parameters such as flange orientations and dimensions that can be adjusted to accommodate different cross-sectional shapes of side members. By changing these parameters within a single design framework rather than creating entirely different component types, the solution adapts to varying geometric requirements while maintaining component standardization.
2Adaptability or versatility
If multiple types of reinforcing members are manufactured for different mounting positions, then the adaptability to varying cross-sectional shapes is improved, but the ease of manufacture deteriorates
Solution Approach 1:
A single reinforcing member design serves multiple mounting positions by utilizing different orientations of its flanges. The L-shaped structure with two flanges can be configured to match various cross-sectional shapes simply by changing which flange faces which direction, eliminating the need to manufacture multiple specialized component types while maintaining full adaptability to geometric variations.
Solution Approach 2:
The design uses adjustable geometric parameters within a unified reinforcing member structure. By varying parameters such as flange orientation angles and positioning rather than creating fundamentally different component types, the solution achieves high adaptability to different cross-sectional shapes while significantly simplifying the manufacturing process.
3Adaptability or versatility
If multiple types of components are used across different mounting positions, then the adaptability to varying cross sections is improved, but the loss of time in component management increases
Solution Approach 1:
The universal reinforcing member design allows the same component type to be used at all mounting positions by simply reorienting the flanges. This eliminates the need for complex component tracking, inventory management, and selection processes that would arise from using multiple specialized types, thereby reducing time loss in component management while maintaining full adaptability to different cross-sectional configurations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution increases the strength of battery unit mounting portions against transverse loads, allows for standardization of components, and simplifies manufacturing by using a single type of reinforcing member across multiple mounting points, reducing costs and complexity.
Implementation Method 1
a pair of flanges which are bent in positions corresponding to a distance between the sidewalls of the side member on the opposite sides of the connecting wall and welded individually to the sidewalls of the side member
Data Source
AI summary
A beam member is fixed to a side member of a vehicle body. The side member is provided with a nut member and a reinforcing member. A bolt is inserted into the nut member from under the side member. The reinforcing member includes first and second plate portions. The first plate portion includes a pair of flanges that are bent individually at bent portions. The respective positions of the bent portions are adjusted depending on a distance between sidewalls of the side member. The flanges are welded to the sidewalls. The second plate portion includes a base portion welded to the lower end of the nut member and an upright portion extending along the nut member.