Modular EV Chassis Frame Joints for Strength and Repairability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional chassis frames for electric vehicles experience reduced coupling forces and material endurance due to repeated forces applied at assembled portions, necessitating improved assembly strength and endurance.
Innovation Solution
A modular chassis frame module with detachable connections and reinforcement parts, including a main frame, front and rear frames with joint parts and auxiliary reinforcement structures, allowing for easy assembly and replacement in limited spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional chassis frames use assembled portions between extruded material and cast material, then the chassis frame can be manufactured with these materials, but the coupling forces are reduced when repeated forces are applied
Solution Approach 1:
The chassis frame is divided into separate front frame, rear frame, and main frame components that can be assembled and disassembled. The front frame includes a first front frame, second front frame, and front joint part. The rear frame includes a first rear frame, second rear frame, and rear joint part. This segmentation allows for modular replacement and maintains structural integrity through designed connection points.
Solution Approach 2:
The chassis frame utilizes both extruded material and cast material in its construction. The main frame, front frames, and rear frames are formed through extrusion processes, while connection components incorporate cast elements. This composite approach allows optimization of each component for its specific functional requirements while maintaining overall structural strength.
2Ease of repair
If a modular chassis frame with detachable connections is used, then part replacement becomes easier and repair costs are reduced, but the device complexity increases
Solution Approach 1:
The chassis frame is divided into separate front frame, rear frame, and main frame components that can be assembled and disassembled. The front frame includes a first front frame, second front frame, and front joint part. The rear frame includes a first rear frame, second rear frame, and rear joint part. This segmentation allows for modular replacement and maintains structural integrity through designed connection points.
Solution Approach 2:
The connection joints between frame components are designed to be detachable and reconfigurable. The front joint part and rear joint part allow for easy assembly and disassembly of the front and rear frames from the main frame, enabling dynamic reconfiguration and simplified maintenance without permanent fixed connections.
3Strength
If reinforcement parts are added to the joint structures, then the assembly strength is improved, but the device complexity increases
Solution Approach 1:
Reinforcement parts are strategically positioned at critical joint locations where stresses are concentrated. The front joint part includes reinforcement elements at the connection points between the first front frame, second front frame, and main frame. The rear joint part similarly includes reinforcement at the second rear frame and main frame connection. This localized reinforcement provides strength exactly where needed without adding unnecessary complexity to the entire structure.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A chassis frame module for an electric vehicle may include: a main frame; a front frame connected to the front of the main frame; and a rear frame connected to the rear of the main frame. The front frame may include: a first front frame disposed at the front of the main frame; a second front frame extending from the first front frame toward the main frame; and a front joint part configured to connect the main frame and the second front frame.