EV Front Frame Motor Mounting for Assembly Tolerance Relief
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Solution Overview
Problem
Existing front frame structures for electric vehicles require high assembly tolerances due to integrated motor mounts, leading to production challenges.
Innovation Solution
A front frame structure with detachable mounting sections between longitudinal and support elements, allowing for larger assembly tolerances and secure fastening via screw connections, with deformable support elements to accommodate variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If motor mounts are firmly integrated into longitudinal members, then structural stability is improved, but assembly tolerance requirements become excessively strict
Solution Approach 1:
The support element is divided into a first portion connected to the longitudinal member and a second portion connected to the cross member, creating a segmented structure that can accommodate tolerances while maintaining stability
Solution Approach 2:
The support element is designed to be elastically or plastically deformable, allowing it to change shape during assembly to absorb tolerance variations, thereby reducing the strictness of assembly tolerance requirements
2Ease of manufacture
If support elements are made deformable to accommodate tolerances, then ease of assembly is improved, but structural strength may be compromised
Solution Approach 1:
The support element has different properties in different regions: the first portion connected to the longitudinal member is designed with specific deformability to accommodate tolerances, while the connection regions maintain sufficient strength to ensure structural integrity
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
Enables reliable and stable motor mounting with reduced assembly constraints, optimizing load distribution across members and ensuring smooth integration.
Implementation Method 1
the support element can be designed to be elastically or plastically deformable in such a way that it can be moved towards the inside of the longitudinal member when the screw connection is tightened
Implementation Method 2
the support element can be designed to be elastically or plastically deformable in such a way that it can be moved towards the inside of the longitudinal member when the screw connection is tightened
Data Source
AI summary
A front frame structure for a chassis of an electric vehicle includes at least two longitudinal members; a cross member connecting the two longitudinal members in the vehicle width direction; at least two support elements, which are assigned to a respective longitudinal member and are connected to the cross member and/or to the respective longitudinal member. A distance is formed between an inner side of the respective longitudinal member and the respective support element, such that a respective mounting section of an electric motor can be inserted between the support element and the respective longitudinal member and can be or is fastened to the support element and the longitudinal member by a screw connection, wherein an axis of rotation of the screw connection runs essentially in the vehicle width direction.