Axle Module Elastic Mounting for Low-Floor EV Ride Comfort
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Solution Overview
Problem
Existing electric vehicles face challenges in achieving optimal driving comfort and maximizing interior compartment space while maintaining a modular construction and low weight, especially in low-floor designs for easy access and crash safety.
Innovation Solution
The electric vehicle features a lattice-like frame structure with coupled axle modules, including wheel hub motors and a centralized battery housing, optimized suspension points, and a crash management system, ensuring torsional rigidity and crash safety, which allows for identical speed and steering behavior in both directions and improved driving comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the axle module is rigidly attached to the frame structure, then the attachment strength and structural stability are improved, but the driving comfort deteriorates due to increased vibrations and noise in the interior compartment
Solution Approach 1:
The patent introduces elastic bearings as an intermediary element between the axle module and the frame structure. These elastic bearings serve as a mediator that transmits necessary forces while filtering out harmful vibrations and noise, thus resolving the contradiction between maintaining strong attachment and reducing interior compartment disturbances.
Solution Approach 2:
The patent changes the mechanical parameters of the connection by using elastic bearings with specific elasticity characteristics. This parameter change allows the connection to be neither fully rigid nor fully flexible, but optimally tuned to transmit essential forces while isolating vibrations and noise from the interior compartment.
2Ease of operation
If the ground clearance is reduced for easy entry and exit, then the accessibility is improved, but the crash safety may deteriorate
Solution Approach 1:
The patent segments the vehicle structure into modular components, including the axle module with integrated crash management system. This segmentation allows the crash management functionality to be independently optimized and positioned to provide safety even with reduced ground clearance, while maintaining ease of access.
Solution Approach 2:
The patent implements a crash management system with crossmembers arranged via crash boxes on the axle module itself, providing beforehand cushioning and protection. This pre-positioned safety mechanism ensures crash safety is maintained even when ground clearance is reduced for better accessibility.
3Device complexity
If the axle module is designed as a compact modular unit with integrated battery housing, then the device complexity is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The patent merges the battery housing with the axle module into a single integrated unit. This combining reduces the overall device complexity by eliminating separate mounting structures and connections, while the modular design allows for standardized manufacturing processes that can maintain precision requirements.
Solution Approach 2:
The axle module is designed as a universal multi-functional unit that integrates drive functions, energy storage (battery housing), and suspension functions. This multi-functionality reduces the number of separate components and simplifies the overall system architecture, while standardized interfaces maintain manufacturing precision.
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 configuration enhances driving comfort by reducing vibrations and noise, maximizing interior space, and ensuring crash safety through optimized suspension and energy source placement, resulting in improved driving behavior and comfort.
Implementation Method 1
at least one of the axle modules has four suspension points for the attachment by means of elastic bearings to the frame structure
Data Source
AI summary
The disclosure relates to an electric vehicle for the transportation of persons and/or loads, having a frame structure and axle modules which are coupled to the frame structure, a front axle module and a rear axle module, to which in each case the wheels are coupled kinematically, at least one of the axle modules having a drive and an energy source. One of the axle modules has four suspension points for the attachment by means of elastic bearings to the frame structure, in each case, two suspension points forming a pair, and the pairs lying at different heights in the motor vehicle vertical direction.