Chassis Structural Element for EV Front-End Crash Energy Dissipation
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Solution Overview
Problem
In electrically driven motor vehicles, the short front-end part, which serves as the crumple zone, poses a risk of short circuits and fires due to backward displacement of components during collisions, particularly affecting the connection panel and battery.
Innovation Solution
A structural element for the chassis comprising fastening sections and a central section that connects these, which is fastened to the motor mount shoe and longitudinal member, dissipates impact energy to support structures, minimizing component displacement and intercepting them before reaching the passenger compartment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the front-end part is designed to be relatively short to achieve a compact traffic area and generous passenger compartment, then the passenger compartment space is increased, but the crash behavior and risk of short circuit worsen due to insufficient crumple zone length
Solution Approach 1:
The structural element is divided into multiple functional sections: a first section that connects to the motor mount shoe, a second section that connects to the longitudinal member, and a third section that provides additional support. This segmentation allows each section to independently manage specific aspects of impact forces, effectively creating a distributed crash management system within the constrained front-end space.
Solution Approach 2:
The structural element extends in multiple spatial dimensions, connecting the motor mount shoe (vertical support) to the longitudinal member (horizontal support) while also providing transverse bracing. This multi-dimensional configuration maximizes the use of available space in the short front-end part to create effective crash management without encroaching on the passenger compartment.
2Weight of moving object
If the front-end part is designed to be relatively short, then the vehicle weight is reduced, but the risk of component displacement and short circuit increases during collision
Solution Approach 1:
The structural element is strategically positioned in the critical zone between the motor mount shoe and the longitudinal member, where component displacement most frequently occurs during collision. By concentrating structural reinforcement in this specific local area, the design prevents harmful component displacement without requiring uniform strengthening throughout the entire front-end part, thus minimizing additional weight.
3Loss of energy
If the structural element is fastened to both the motor mount shoe and longitudinal member, then the impact energy dissipation is improved, but the device complexity increases
Solution Approach 1:
The structural element simultaneously performs multiple functions: it acts as a load transfer path between the motor mount shoe and longitudinal member, provides direct bracing against component displacement, and serves as an additional crash management structure. By consolidating these multiple functions into a single element, the design achieves effective impact energy dissipation without proportionally increasing device complexity.
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
Reduces the risk of short circuits by efficiently directing impact energy into the chassis, thereby preventing component displacement towards critical areas.
Implementation Method 1
the backward displacement of components, for example of a drive unit, in the front-end part of the motor vehicle may be minimized by way of impact energy being dissipated to supporting structures of the chassis
Data Source
AI summary
A structural element for a motor vehicle chassis, particularly a chassis of an electrically powered motor vehicle, includes at least two securing sections and a central section which connects the two securing sections. Each securing section can be secured to an outer surface of a motor mounting element of the chassis and/or to an outer surface of a longitudinal member of the chassis.