Dual-Frame Vehicle Chassis Layout for Battery Space and Crash Loads
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Solution Overview
Problem
Existing chassis assemblies for heavy-duty vehicles with electric propulsion systems face challenges in providing sufficient space for large energy storage systems while effectively managing forces during frontal crashes and ensuring impact protection for the energy storage systems.
Innovation Solution
A chassis assembly with an upper frame structure, a front crash structure, and a lower frame structure, where the upper and lower frame structures are connected to the front crash structure, providing improved reinforcement and impact protection for energy storage systems, such as batteries, while optimizing space and load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a conventional chassis structure with two longitudinally extending beams is used, then the main frame structure is simple, but it cannot provide sufficient space for large energy storage systems and cannot effectively handle forces during frontal crashes
Solution Approach 1:
The chassis assembly is divided into an upper frame structure and a lower frame structure, with the upper frame containing longitudinally extending upper side regions and the lower frame containing longitudinally extending lower beams. This segmentation allows the energy storage system to be positioned in the space between the upper and lower frames, providing sufficient volume while maintaining structural strength for crash force handling through the distributed frame architecture.
2Quantity of substance
If the battery size is increased to cover long driving range, then the energy storage capacity is improved, but the chassis structure becomes more complex and the impact protection requirements increase
Solution Approach 1:
The upper frame structure and lower frame structure serve multiple functions: they provide structural support for the chassis, define the space for positioning large energy storage systems, and work together to handle crash forces. The upper side regions and lower beams both contribute to impact protection, allowing the structure to accommodate increased battery capacity without proportionally increasing complexity.
3Strength
If reinforcement structure is added to handle frontal crash forces, then the crash resistance is improved, but the weight and cost of the chassis assembly increases
Solution Approach 1:
The chassis assembly features local reinforcement through the lower frame structure with longitudinally extending lower beams that are specifically positioned to handle frontal crash forces. The lower connection portions provide targeted reinforcement at critical locations where crash forces are transmitted, rather than uniformly increasing the strength of the entire chassis assembly, thus minimizing unnecessary weight addition.
Data Source
AI summary
A chassis assembly for a vehicle is provided. The chassis assembly includes: an upper frame structure having at least two longitudinally extending upper side regions arranged on opposite sides of a longitudinal centre line. The upper side regions are connected to each other by upper connection portions. A front crash structure is configured to absorb energy during an impact generated from a vehicle collision, and extends in a transverse direction. The upper frame structure is connected to said front crash structure; wherein said chassis assembly further comprises: a lower frame structure having at least two longitudinally extending lower beams arranged on opposite sides of the longitudinal centre line, said lower beams being connected to each other by lower connection portions, and said lower frame structure is connected to said upper frame structure and to said front crash structure.