Deformable Electric Vehicle Front Frame Structure
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Solution Overview
Problem
Conventional frame structures in electric vehicles are not adequately designed to support electric motors in the front portion, particularly during frontal collisions, as they are not adapted for deformation and energy absorption, leading to complex and costly designs.
Innovation Solution
A deformable front frame structure with side members configured to bend inwardly or outwardly, supported by a cross member with elongated fastening elements and enlarged holes to allow initial bending deformation without pressing the fastening element onto the hole edges, enabling controlled energy absorption during collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional engine mounts are used to support the electric motor, then the motor can be supported in the front portion, but the design becomes complex and costly due to the need for large breakable mounts
Solution Approach 1:
The cross member serves multiple functions: it supports the electric motor during normal operation and acts as a structural element that allows controlled deformation during frontal collisions. By making the cross member itself deformable rather than using separate breakable mounts, the design achieves collision energy absorption without requiring complex specialized mounting arrangements.
Solution Approach 2:
The invention extracts the collision energy absorption function from the motor mounting system and integrates it into the cross member structure. Instead of having separate breakable engine mounts for collision protection, the cross member is designed to deform independently, separating the motor support function from the collision management function while simplifying the overall design.
2Stability of the object's composition
If rigid mounting is used to securely support the electric motor, then the motor support is stable, but the side members cannot deform during frontal collisions to absorb energy
Solution Approach 1:
The mounting arrangement transitions from a static rigid connection to a dynamic system that adapts during collisions. The elongated fastening elements allow the cross member to deform longitudinally during frontal impacts, enabling energy absorption while maintaining motor support stability during normal operation. The system dynamically adjusts its rigidity based on the collision conditions.
Solution Approach 2:
The fastening elements are designed with elongated geometry that changes the mechanical parameters of the mounting system. The increased length allows greater deformation range while maintaining adequate motor support. This parameter change enables the system to achieve both stable motor mounting and controlled deformation during collisions by altering the fastening element dimensions rather than the motor mount design.
3Ease of manufacture
If standard holes are used in the cross member for fastening elements, then the manufacturing is simple, but the fastening elements press onto hole edges during deformation preventing initial bending
Solution Approach 1:
The cross member features localized quality changes at specific positions where fastening elements are installed. The holes are enlarged only in the regions where deformation occurs, while other parts of the cross member maintain standard dimensions. This local modification allows deformation without compromising overall structural integrity or manufacturing simplicity in non-critical areas.
Solution Approach 2:
The hole geometry is segmented into different zones: standard circular sections for manufacturing simplicity and enlarged sections for deformation accommodation. This segmentation allows the cross member to maintain ease of manufacture for the majority of its structure while having specific localized regions that facilitate controlled deformation during collisions.
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 design allows for efficient energy absorption and controlled deformation of the side members, reducing the complexity and cost of the frame structure while ensuring safety during frontal collisions.
Implementation Method 1
each of the side members, at least along a deformable section thereof, is configured to deform by bending in an inwards and/or outwards transversal direction when compressed by a longitudinally directed force exceeding a threshold value
Implementation Method 2
the fastening element extends through a first hole in the cross member and a second hole in the corresponding side member, wherein at least one of the first and second holes, at least in the transversal direction, is substantially larger/wider than a diameter of the fastening element so as to allow at least an initial bending deformation of the side member without pressing the fastening element onto an edge of the larger/wider hole
Data Source
AI summary
A vehicle, including: an electric motor operatively connected to at least one driving wheel of the vehicle, and a frame structure including first and second side members extending in a longitudinal direction along opposite sides of the vehicle and at least one cross member extending in a transversal direction of the vehicle and being connected to the first and second side members, wherein the electric motor is supported by the frame structure such that the electric motor is arranged in a front portion of the vehicle in association with a pair of front wheels of the vehicle, and wherein each of the side members, at least along a deformable section thereof, is configured to deform by bending in an inwards and/or outwards transversal direction when compressed by a longitudinally directed force exceeding a threshold value, such as in case the vehicle is subject to a sufficiently energetic frontal collision.