Electric Vehicle Chassis Layout for Battery Packaging and Vibration Isolation
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Solution Overview
Problem
Commercial vehicles with electric powertrains face packaging challenges due to live axle suspension configurations, which prevent efficient integration of batteries and expose drive units to high vibration, affecting reliability and limiting space for other components.
Innovation Solution
A chassis configuration for electric commercial vehicles that positions the electric motor and drivetrain between the frame rails, using a dead axle suspension, allowing batteries to be disposed within the frame rails and eliminating the need for a driveshaft, thus improving packaging and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a live axle suspension configuration is used, then high load capacity is achieved, but packaging efficiency deteriorates due to inability to integrate batteries within frame rails
Solution Approach 1:
The suspension system is segmented into two independent functions: a dead axle beam suspension for load bearing and a separate CV axle for power transmission. This allows the battery to be positioned within the frame rails without interfering with the suspension components, resolving the packaging conflict while maintaining load capacity.
Solution Approach 2:
The power transmission function is extracted from the live axle configuration and implemented through a separate CV axle. This extraction allows the battery to occupy the space between frame rails that would otherwise be required for driveshaft accommodation in traditional live axle configurations.
2Device complexity
If a live axle suspension configuration is used, then drive shaft integration is achieved, but reliability deteriorates due to high vibration exposure
Solution Approach 1:
The electric motor and drivetrain are extracted from the suspension system and mounted to the vehicle frame. This separation removes the drive unit from the high-vibration environment of the live axle, improving reliability while maintaining the integrated power transmission capability through the CV axle.
Solution Approach 2:
A CV axle serves as an intermediary component between the frame-mounted drivetrain and the wheel hub. This allows power transmission without direct coupling of the motor to the suspension, isolating the drive unit from vibration while maintaining functional integration.
3Power
If a driveshaft configuration is used, then power transmission is achieved, but packaging efficiency deteriorates due to space occupation between frame rails
Solution Approach 1:
The power transmission path is reconfigured to transmit power laterally from the frame to the wheel hub through the CV axle, rather than longitudinally through a driveshaft between frame rails. This dimensional change in power transmission path frees up the frame rail space for battery integration.
Data Source
AI summary
Described herein are methods and systems of a chassis of a commercial electric vehicle. In various embodiments, the chassis may include a ladder frame with a plurality of frame rails. Batteries and drive units may be packaged within the frame rails of the ladder frame. The chassis may further include an independent front suspension and batteries may be disposed between the suspension members of the independent front suspension.