Vehicle Crossmember Wiring Bracket for EV Retrofit Packaging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge is to integrate new components such as high-voltage batteries and their associated pipes and cables into a pre-existing vehicle structure with reduced overhang, while minimizing spatial constraints and avoiding modifications to the existing structure.
Innovation Solution
A fixing part is integrated into the reinforcement crossmember of the vehicle apron, featuring specific fixing zones for pipes and wiring, allowing for secure attachment without altering the existing structure, including a first part fixed directly to the reinforcement crossing and a second part with complementary fixing means to prevent rotation, supporting various components like brake fluid pipes, heating, and battery management systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If new components (high-voltage battery, charging socket) are installed in a pre-existing vehicle structure with reduced overhang, then the vehicle can be produced with reduced development costs by reusing thermal vehicle platforms, but the spatial arrangement constraints for pipes and cables increase significantly
Solution Approach 1:
The fixing part is divided into a first part that attaches to the reinforcement cross member and a second part that provides fixing zones for pipes and cables. This segmentation allows the fixing part to be installed in the limited space available in the reduced overhang structure while providing adequate mounting points for the new components.
Solution Approach 2:
The fixing part acts as an intermediary element between the pre-existing reinforcement cross member and the new pipes/cables required for the high-voltage battery and charging socket. It bridges the gap between the existing structure and new components without requiring modification of the original vehicle structure.
2Reliability
If the fixing part includes multiple parts with complementary fixing means, then rotational movement is prevented and reliability increases, but the device complexity increases
Solution Approach 1:
The complementary fixing means feature asymmetric geometries (square hole with stud, circular hole with curved end) that prevent rotational movement of the second part relative to the first part. This asymmetric design ensures reliable positioning while maintaining a relatively simple overall structure.
3Ease of manufacture
If the first part is directly fixed to the reinforcement cross member, then the existing vehicle structure does not need to be modified, but the available space for routing new pipes and cables is limited
Solution Approach 1:
The fixing part extends in multiple dimensions from the reinforcement cross member, creating a three-dimensional structure that provides fixing zones in various directions. This allows pipes and cables to be routed and fixed in the limited space available without requiring modification of the original vehicle structure.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Arrangement (50) for motor vehicle (100), comprising - a fastening piece (1), - a cross member (51) for reinforcing an apron (53) of a motor vehicle (100), - at least one first wiring (45, 46) intended to connect a charging socket (69) of the motor vehicle (100) to a high-voltage battery (61) of the motor vehicle (100), characterized in that the fastening piece (1) is fixed to the reinforcing cross member (51) and includes a first fastening area (115) for at least one wiring (45, 46).