EV Chassis Collision Structure for Battery Pack Deformation Control
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Solution Overview
Problem
New energy vehicles face challenges in collision performance due to adverse deformation of sub-frames and inadequate protection of battery packs during collisions, leading to safety risks.
Innovation Solution
A chassis collision structure for new energy vehicles comprising a front lower collision beam assembly, front sub-frame assembly, front and rear battery pack bottom fenders, and rear sub-frame assembly, with energy-absorbing boxes and specific connecting parts to guide deformation and enhance protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If full-frame sub-frames are equipped to ensure performance, then strength and reliability are improved, but dimensions and weight increase, affecting collision performance due to adverse deformation
Solution Approach 1:
The sub-frame is divided into multiple components: front sub-frame assembly, rear sub-frame assembly, front battery pack bottom fender, and rear battery pack bottom fender. Each segment serves specific collision management functions, allowing the structure to be optimized locally rather than requiring a heavy full-frame design throughout.
Solution Approach 2:
Different regions of the chassis are given different structural properties. The front and rear sub-frame assemblies have different configurations, and battery pack bottom fenders are added specifically at battery locations. This localized optimization allows strength to be concentrated where needed while reducing overall weight.
2Reliability
If full-frame sub-frames are equipped to ensure performance, then reliability is improved, but device complexity increases
Solution Approach 1:
The chassis collision structure is segmented into modular assemblies (front sub-frame, rear sub-frame, battery bottom fenders) that can be independently designed, manufactured, and assembled. This modularity improves reliability through specialized design in each segment while managing overall system complexity.
Solution Approach 2:
The front and rear sub-frame assemblies serve multiple functions: structural support, collision force management, and battery pack protection. This multi-functionality reduces the need for separate dedicated components, thereby managing complexity while maintaining reliability.
3Device complexity
If battery packs are protected by plastic guard boards or left exposed, then device complexity is reduced, but safety and reliability deteriorate during collisions or dragging bottom
Solution Approach 1:
Battery pack protection is implemented locally at the bottom of the battery pack using dedicated bottom fenders. These fenders provide targeted protection against bottoming-out and collision damage without requiring comprehensive protection structures throughout the entire vehicle, thus maintaining safety while controlling complexity.
Solution Approach 2:
The battery pack bottom fenders are designed to absorb and distribute collision forces before they reach the battery pack. This pre-cushioning effect protects the battery from direct impact during collisions or dragging incidents, improving safety without requiring complex active protection systems.
4Ease of manufacture
If force-transfer passages on bodies are provided, then some collision performance is achieved, but protection requirements in MPDB and other collision conditions are not met
Solution Approach 1:
The collision management system is segmented into specialized front and rear assemblies with distinct force-transfer pathways. The front sub-frame assembly handles frontal collision forces, while the rear sub-frame assembly manages rearward forces, ensuring compliance with various collision standards including MPDB through dedicated design in each segment.
Solution Approach 2:
The structural parameters (geometry, material properties, connection methods) of the sub-frame assemblies are specifically optimized to meet different collision test requirements. By adjusting these parameters in the front and rear assemblies, the system achieves compliance with multiple collision standards while maintaining ease of manufacture.
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 structure improves collision performance by directing deformation in specific areas and providing enhanced protection for battery packs, thereby enhancing safety during collisions.
Implementation Method 1
the front lower collision beam assembly includes energy-absorbing boxes which are arranged on two sides
Data Source
AI summary
The present disclosure provides a chassis collision structure of a new energy vehicle, comprising a front lower collision beam assembly, a front sub-frame assembly, a front battery pack bottom fender, a rear battery pack bottom fender, and a rear sub-frame assembly which are arranged sequentially along a direction from a head to a tail of a vehicle, wherein the front lower collision beam assembly is connected to a front end of the front sub-frame assembly; the front battery pack bottom fender is connected to a bottom of the front sub-frame assembly; the rear battery pack bottom fender is connected to a bottom of the rear sub-frame assembly; and connecting parts which are connected with a battery pack are arranged at one end of the front battery pack bottom fender and one end of the rear battery pack bottom fender, which are close to each other, respectively.