Energy Storage Floor Assembly With Crash Load Transfer Element
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Solution Overview
Problem
Existing energy storage floor assemblies in electrically drivable motor vehicles face challenges in dissipating deformation energy during a crash without damaging the high-voltage storage units or storage cells, while maintaining structural integrity and avoiding weight and space constraints.
Innovation Solution
An energy storage floor assembly with a load transmission element inserted between the front-axle support and longitudinal beam, allowing controlled deformation and energy dissipation, preventing direct impact on the storage unit, and ensuring optimal force transmission through longitudinal beams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the front-axle support is directly bolted to the longitudinal beam, then the structural connection is simple and strong, but the front-axle support cannot dissipate crash energy effectively and may damage the energy storage device
Solution Approach 1:
A load transmission element is introduced as an intermediary component between the front-axle support and the longitudinal beam. This element features a front supporting region that contacts the front-axle support and a rear supporting region that contacts the longitudinal beam, enabling controlled force transmission while preventing direct impact on the energy storage device during crash events
Solution Approach 2:
The load transmission path is segmented into distinct functional zones: the front supporting region handles crash load absorption from the front-axle support, the rear supporting region transfers forces to the longitudinal beam, and intermediate sections provide controlled deformation. This segmentation allows each region to be optimized for its specific function while maintaining overall structural integrity
2Loss of energy
If the front-axle support is designed for maximum energy dissipation through large deformation, then crash energy is effectively absorbed, but the deformation path may be uncontrolled and impact the energy storage floor assembly
Solution Approach 1:
The load transmission element serves as a mediator that channels and controls the deformation path of the front-axle support. By providing defined front and rear supporting regions, it ensures that crash-induced deformation occurs in a controlled manner along the longitudinal beam rather than allowing uncontrolled movement that could damage the energy storage device
Solution Approach 2:
The load transmission element is pre-positioned between the front-axle support and the energy storage floor assembly to provide beforehand cushioning. This element absorbs and distributes crash forces before they can reach the energy storage device, preventing direct impact while enabling the front-axle support to deform for energy dissipation
3Reliability
If longitudinal beams are used to support the load transmission element, then force transmission is optimized and the energy storage device is protected, but the installation space and weight of the vehicle body increase
Solution Approach 1:
The longitudinal beams serve multiple functions: they provide structural support for the energy storage floor assembly, act as load transmission paths for crash forces, and support the load transmission element during deformation events. This multi-functionality eliminates the need for separate dedicated crash load-bearing structures, optimizing force transmission without proportionally increasing weight
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
The solution enables controlled deformation of the front-axle support, maximizing energy dissipation and preventing damage to the high-voltage storage unit by supporting the front-axle support on longitudinal beams via load transmission elements, thus ensuring structural integrity and safety.
Implementation Method 1
in the event of its crash-induced displacement to the rear is supported on each longitudinal beam in the storage housing by way of the respective load transmission element, and thus a further crash-energy-dissipating deformation of the front-axle support can commence
Data Source
AI summary
An energy storage floor assembly for a motor vehicle having an electric drive includes an electrical energy storage device accommodated in a storage housing and arranged on the bottom side of a vehicle floor. At least one longitudinal beam is arranged within the storage housing. The front end of the longitudinal beam, viewed in the vehicle direction, is connected at least indirectly to a crossbeam component which is arranged in the region of a front-end structure and to which a front axle carrier is also attached. A load transfer element is installed between a rearward region of the front axle carrier and the front end of the longitudinal beam, which load transfer element has a front support region on the front end thereof and a rear support region on the rear end thereof. In an event of an accident-induced backward movement of the axle carrier as a result of a collision, the axle carrier can be supported on the front support region of the load transfer element, the rear support region of which can be supported at least indirectly on the longitudinal beam.