EV Floor Battery Mount With Rear Cross-Member Support
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Solution Overview
Problem
Existing passenger car designs face challenges in integrating a flat energy store below the body/floor assembly for electric vehicles (BEV) while maintaining the rigidity of the rear axle mount and securely fastening the energy store without interfering with torsion struts typically used in internal combustion engine (ICE) vehicles.
Innovation Solution
A combined floor assembly and energy store design featuring a cross member that supports the rear axle mount and securely fastens the energy store to the floor assembly, allowing separate mounting and dismantling of components, and serves as a bollard and underbody guard.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a flat energy store is integrated below the body/floor assembly for electric vehicles, then sufficient electric range is provided, but the torsion struts cannot be retained and the rear axle mount rigidity is compromised
Solution Approach 1:
The holding element is designed to perform multiple functions: it supports the rear axle mount to maintain rigidity, fastens the energy store to the floor assembly, and serves as a structural connector. This multi-functionality resolves the contradiction by allowing the energy store integration while preserving the rear axle mount support structure.
2Reliability
If the energy store is fastened to the floor assembly before the marriage of floor assembly to drive and chassis, then the energy store is securely fixed, but the energy store may hang freely and deflect during assembly
Solution Approach 1:
The holding element is pre-installed on the floor assembly before the energy store is mounted. This preliminary action provides immediate support and positioning for the energy store, preventing it from hanging freely or deflecting during the assembly process while ensuring secure fastening.
3Ease of manufacture
If existing components and structures are retained for constructing electric drive variants on the same production line, then costs are kept low, but the torsion struts cannot be used due to energy store installation space
Solution Approach 1:
The holding element acts as an intermediary component that bridges the floor assembly and the rear axle mount, enabling the integration of the energy store in the available space without interfering with the torsion strut mounting points. This allows existing production line components to be retained while accommodating the energy store.
Data Source
AI summary
A combined floor assembly and energy storage device for an electrically driven passenger car includes a floor assembly on the lower face of which an energy storage device of an electric drive of the passenger car is arranged. A holding element, by which a rear end region of the energy storage device is held on the lower face of the floor assembly, and a rear cross-member, which is arranged on the lower face of the floor assembly and behind the energy storage device in the vehicle longitudinal direction are provided. In order to provide a combined floor assembly and energy storage device which offers especially rigid support for the rear cross-member even in a vehicle with a purely electric drive and in which, additionally, the energy storage device is fixed to the rear end on the lower face of the floor assembly in a particularly stable manner, the energy storage device is secured to the rear cross-member by way of the holding element.