Drivetrain Charging Socket Mounting for EV Assembly

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Solution Overview

Problem

The assembly of electric vehicles is complicated by the need to integrate charging sockets, which are often difficult to position ergonomically and require protection during the joining of the drivetrain to the vehicle body, leading to increased complexity and potential damage to charging lines.

Innovation Solution

A method where the drivetrain and vehicle body are aligned for easy fastening, with an electrical connecting element like a charging socket fixed to a chassis part, allowing for improved ergonomics and reduced repositioning needs, and optionally using a holder to manage the socket's placement, enabling efficient and ergonomic installation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of time

If the charging socket is mounted on the bodywork before the marriage assembly step, then the charging socket can be installed in advance, but the charging line is exposed to damage risk during the marriage process

Engineering Contradiction:

Improveassembly timeVSAvoidcharging line protection

Core Design Contradiction:

Loss of timeVSReliability

Solution Approach 1:

The charging socket is mounted on the drivetrain in advance before the marriage assembly step, allowing preliminary installation while the drivetrain is still accessible. The charging line is then routed through the drivetrain structure to reach the bodywork, ensuring the line is protected during the marriage process when the drivetrain and bodywork are joined together.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the charging socket is mounted on the bodywork after the marriage assembly step, then the charging line is protected during assembly, but manual assembly becomes extremely difficult due to poor accessibility

Engineering Contradiction:

Improvecharging line protectionVSAvoidmanual assembly ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The charging socket is installed on the drivetrain before the marriage assembly step when the drivetrain is still accessible and maneuverable. This preliminary installation avoids the need for difficult manual assembly operations after the marriage when accessibility is severely limited by the joined drivetrain and bodywork structure.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If the charging socket is mounted on the drivetrain, then accessibility and ergonomics are improved, but additional fastening points are required on the drivetrain

Engineering Contradiction:

ImproveaccessibilityVSAvoidfastening structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The drivetrain structure serves multiple functions: it provides the mechanical drive function and simultaneously serves as a mounting structure for the charging socket. By utilizing existing drivetrain components and structures for dual purposes, the need for additional dedicated fastening points is minimized, reducing overall device complexity while maintaining improved accessibility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11565633B2Method for joining a drivetrain to a vehicle body

Publication Date: 2023.01.31 BAYERISCHE MOTOREN WERKE AG

AI summary

A method for joining a drivetrain to a vehicle body, includes the steps of: transferring the drivetrain and the vehicle body into a joining position, arranging an electrical connecting element on a chassis part of the drivetrain, and joining the drivetrain to the vehicle body, wherein the drivetrain and the vehicle body are connected together at predetermined points via fasteners.