EV Front Frame Structure With Inclined Crush Paths
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Solution Overview
Problem
In electric vehicles, the rigid power unit and high-voltage control unit pose challenges in absorbing impact energy during frontal collisions, potentially leading to cabin and battery chamber deformation.
Innovation Solution
A front frame structure is designed with front side frames, a bumper beam, and a lower frame, which are strategically positioned to absorb impact energy by utilizing extra spaces in the motor room and incorporating inclined surface portions for efficient energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the power unit is designed as a rigid body for high-voltage control, then the control unit can be mounted above the power unit in a compact space, but the rigid structure cannot absorb impact energy during frontal collisions
Solution Approach 1:
The front frame structure is divided into multiple functional segments: the bumper beam for initial impact absorption, the front side frames with inclined surface portions for controlled deformation, and the lower frame for structural support. This segmentation allows different parts to perform different functions - the rigid power control unit remains protected while the frame structure absorbs impact energy through controlled deformation of specific segments.
Solution Approach 2:
The front frame structure acts as an intermediary between the external impact and the rigid power control unit. The inclined surface portions of the front side frames and the lower frame create a deformation zone that mediates the impact force, allowing energy absorption through controlled structural deformation while protecting the high-voltage components mounted above the power unit.
2Object-affected harmful factors
If the power unit is retreated by impact in a frontal collision, then impact energy can be absorbed, but the cabin may be deformed
Solution Approach 1:
The front side frames with inclined surface portions are pre-configured to deform in a controlled manner during impact. The geometry of these inclined surfaces is designed beforehand to guide the deformation path, ensuring that energy absorption occurs through predictable frame deformation rather than uncontrolled cabin intrusion. This preliminary structural design prevents cabin deformation while maintaining impact absorption capability.
Solution Approach 2:
The inclined surface portions of the front side frames introduce a geometric dimension that transforms the impact response. Instead of direct linear compression that would transmit force to the cabin, the inclined surfaces convert the impact into a combination of axial and lateral deformation components, absorbing energy through a more complex deformation mode that protects the cabin structure.
3Volume of moving object
If the control unit is mounted above the power unit to save space, then the motor room utilization is improved, but the control unit may be crushed by impact
Solution Approach 1:
The front frame structure with its inclined surface portions and lower frame configuration creates a cushioning zone before the impact reaches the power control unit. This preliminary deformation structure absorbs and dissipates impact energy through controlled frame deformation, providing protective cushioning that prevents the high-voltage control unit mounted above the power unit from being crushed during frontal collisions.
4Quantity of substance
If the entire space under the floor is used as a battery chamber, then the battery capacity is maximized, but the battery chamber may deform during frontal collision
Solution Approach 1:
The front side frames with inclined surface portions are pre-configured to deform in a controlled manner during impact, creating a deformation zone that absorbs energy before it can reach the battery chamber. This preliminary structural response prevents direct impact transmission to the battery chamber, maintaining its structural integrity while allowing maximum battery accommodation space.
Data Source
AI summary
In a front frame structure for an electric vehicle, front side frames disposed in extra spaces between side walls of a motor room and side surfaces of a power control unit include a wall-shaped portion in a rear region and an arm-shaped portion in a front portion. A first inclined surface portion is formed in a lower portion of the wall-shaped portion to extend forward from a rear portion. A second inclined surface portion is formed on a bottom surface of the arm-shaped portion to extend forward from an end of the first inclined surface portion. Lower side frames of the lower frame and the front side frames are joined while being reinforced via front reinforcements. Side surfaces of an upper valley line portion joining the inclined surface portions and side surfaces of the lower side frame facing a lower side of the line portion are coupled via rear reinforcements.