EV Chassis Collision Structure for Guided Battery Pack Protection
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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 and non-compliance with regulatory requirements.
Innovation Solution
A chassis collision structure comprising a front lower collision beam assembly, front sub-frame assembly, front battery pack bottom fender, rear battery pack bottom fender, and rear sub-frame assembly, arranged sequentially along the vehicle length, with energy-absorbing boxes and collapsing deformation intervals to guide deformation and enhance collision 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 device complexity and weight increase
Solution Approach 1:
The sub-frame structure is divided into multiple components including front sub-frame, rear sub-frame, front lower collision beam assembly, and battery pack bottom fenders. Each segment serves specific functions and can be optimized independently, reducing overall complexity while maintaining strength.
Solution Approach 2:
Different parts of the sub-frame structure have different structural characteristics optimized for their specific functions. The front lower collision beam assembly has energy-absorbing boxes for collision protection, while the battery pack bottom fenders provide localized protection for battery packs, avoiding unnecessary complexity in other areas.
2Reliability
If full-frame sub-frames are equipped to ensure performance, then collision performance is improved, but weight increases
Solution Approach 1:
The sub-frame is segmented into functional modules that can be optimized for weight. The battery pack bottom fenders and front lower collision beam assembly are separate components that provide collision protection only where needed, reducing unnecessary weight in other areas.
Solution Approach 2:
The structure uses varying wall thicknesses and cross-sectional dimensions in different areas to optimize the strength-to-weight ratio. Energy-absorbing boxes have specific dimensional parameters designed to absorb collision energy efficiently while minimizing weight.
3Device complexity
If battery packs are protected by plastic guard boards or left exposed, then device complexity is reduced, but safety and reliability deteriorate
Solution Approach 1:
The battery pack bottom fenders provide localized protection specifically for the battery packs and connecting parts. This targeted approach protects critical components without requiring a complex overall protection structure, maintaining simplicity while improving safety.
Solution Approach 2:
The battery pack bottom fenders act as intermediary protective structures between the battery packs and external collision forces. These fenders absorb and distribute impact forces, protecting the battery packs without requiring direct complex protection on each battery unit.
4Device complexity
If only force-transfer passages on bodies are provided, then device complexity is reduced, but collision performance deteriorates
Solution Approach 1:
The collision structure is segmented into multiple functional components including front lower collision beam assembly with energy-absorbing boxes, battery pack bottom fenders, and sub-frame assemblies. Each segment handles specific collision scenarios, providing comprehensive protection without excessive complexity.
Solution Approach 2:
Different parts of the collision structure have specialized characteristics: the front lower collision beam assembly has energy-absorbing boxes for frontal collisions, while the battery pack bottom fenders provide localized protection for battery areas, optimizing collision performance for different scenarios without uniform complexity throughout.
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 proposed structure improves the collision performance of new energy vehicles by guiding deformation in specific areas, enhancing the protection of battery packs and compliance with safety standards, thereby reducing safety risks and meeting regulatory requirements.
Implementation Method 1
energy-absorbing boxes and collapsing deformation intervals to guide deformation and enhance collision protection
Data Source
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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. According to the chassis collision structure of the new energy vehicle of the present disclosure, an collision system which is located at a vehicle chassis is formed, so that the deformation of the chassis structure may be guided to caused or increased in specific areas, thereby improving the collision performance of the chassis of the new energy vehicle.