BEV Conversion Chassis Merger Module for Battery Space and Torque
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Solution Overview
Problem
Existing chassis designs for converting internal combustion engine (ICE) vehicles to battery electric vehicles (BEVs) face challenges in maximizing battery packaging density, require complex assembly, generate material waste, and lack robustness to handle high torques from electric motors.
Innovation Solution
A method involving shortening the ICE chassis, retaining the rear axle and suspension, adding a new chassis part with wider longitudinals and crossmembers, and using a merger module with motor mounting plates and spacers to connect the frames, allowing for modular assembly and improved torque support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional crossmembers are used to stiffen the frame, then frame strength is improved, but the available space between longitudinal frame rails is reduced
Solution Approach 1:
A merger module is introduced as an intermediary component that connects the old and new chassis parts. This module includes mounting plates and spacers that provide structural reinforcement without occupying the space between the longitudinal frame rails, thus resolving the contradiction between frame strength and available space.
Solution Approach 2:
The crossmembers are repositioned from the interior space between frame rails to the exterior, mounted on the outer surfaces of the longitudinal frame rails. This dimensional relocation maintains frame stiffening functionality while preserving maximum interior volume for battery packaging.
2Loss of substance
If the chassis is converted by joining old and new parts, then component waste is reduced, but assembly complexity increases
Solution Approach 1:
The conversion process is segmented into modular components: the old chassis part, the merger module, and the new chassis part. Each segment can be prepared independently and then assembled together using standardized mounting interfaces, reducing overall assembly complexity despite the multi-component nature of the solution.
Solution Approach 2:
The merger module serves multiple functions simultaneously: it connects the old and new chassis parts, provides structural reinforcement, accommodates the electric motor mounting, and enables width adjustment. This multi-functionality reduces the need for separate components, simplifying the overall assembly process.
3Volume of moving object
If a wider frame is assembled to maximize battery space, then battery packaging density is improved, but torque strength requirements increase
Solution Approach 1:
The chassis structure uses composite construction combining the original metal frame rails with added reinforcement plates and spacers. This composite approach creates a wider frame configuration that maintains high torque strength while maximizing the interior volume available for battery packaging.
4Adaptability or versatility
If custom merger modules are manufactured for each conversion, then adaptability is improved, but manufacturing costs increase
Solution Approach 1:
The merger module is designed as a universal component that can be applied to multiple different chassis configurations. By standardizing the mounting interfaces and dimensions, the same basic module design can serve multiple conversion projects, reducing per-unit manufacturing costs while maintaining adaptability.
Data Source
AI summary
A chassis frame structure consisting of the merger of two chassis frames with different widths, which include a module to facilitate the difference in size as well as integrate an electric motor drive solution for the purpose of battery electric commercial vehicles. The module mounting structure includes a plurality of brackets allowing for form-fit assembly of an existing vehicle chassis frame with a new pre-assembled chassis frame.