EV Conversion Kit With Motor-Axle Integration and Central Battery Layout
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Solution Overview
Problem
The conversion of internal combustion engine vehicles to electric vehicles is costly, time-consuming, and often results in inefficient powertrains due to the retention of existing transmissions and the need for custom battery placement, limiting market viability and accessibility.
Innovation Solution
An electric vehicle conversion kit that integrates the electric motor and axle as a single unit, allowing for direct coupling or mechanical connection via a driveshaft, and optimizes battery placement between the frame rails, eliminating the need for the IC motor, transmission, and fuel tank, thus freeing up space and improving weight distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the existing transmission is retained during conversion, then the conversion process is simplified, but the efficiency of the EV powertrain deteriorates
Solution Approach 1:
The patent removes the existing transmission system from the vehicle during conversion, extracting only the necessary components (axles, suspension) while eliminating the inefficient transmission mechanism. This allows direct connection of the electric motor to the axles, resolving the contradiction by sacrificing manufacturing simplicity to achieve energy efficiency.
2Volume of moving object
If custom battery boxes are created to house batteries in multiple places, then the existing engine compartment space is utilized, but the vehicle stability deteriorates and cabin space is reduced
Solution Approach 1:
The patent relocates batteries from multiple distributed locations (engine compartment, under seats) to a single centralized location in the vehicle's undercarriage. This dimensional relocation resolves the contradiction by consolidating battery volume into one space, thereby improving vehicle stability and freeing up cabin space while still utilizing available vehicle volume.
3Volume of moving object
If batteries are installed in tightly engineered battery boxes, then space utilization is optimized, but the ease of repair and maintenance deteriorates
Solution Approach 1:
The patent employs removable battery packs with standardized mounting interfaces that allow dynamic reconfiguration. The batteries can be easily removed and replaced without disassembling the entire vehicle structure, resolving the contradiction by making the battery system adaptable and maintainable while still optimizing space utilization through centralized placement.
4Adaptability or versatility
If bespoke conversions are performed requiring complete restoration, then the vehicle is customized to specific specifications, but the conversion cost and time increase significantly
Solution Approach 1:
The patent divides the conversion process into modular segments: removable battery packs, standalone electric motor assembly, and separable axle components. This segmentation allows for standardized, pre-fabricated modules that can be quickly installed, resolving the contradiction by enabling customization through modular assembly rather than complete restoration.
Solution Approach 2:
The patent utilizes pre-fabricated electric motor assemblies and standardized battery packs that are prepared in advance. These pre-assembled components eliminate the need for on-site customization work, resolving the contradiction by allowing vehicle-specific adaptations while maintaining quick installation through pre-prepared modules.
Data Source
AI summary
Electric vehicle conversion kits for IC vehicles and converted electric vehicles. An electric vehicle conversion kit may include an electric motor directly coupled to an axle. Another electric vehicle conversion kit may include an electric motor mechanically coupled to an axle via a driveshaft. Another electric vehicle conversion kit may include an electric motor coupled to a transfer case.