EV Motor Shield Box Structure for Lightweight Frame Integration
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Solution Overview
Problem
Integration of attachment structures for electric vehicle motors into existing vehicle structures is challenging, requiring innovative solutions to support the motor effectively while minimizing weight and complexity.
Innovation Solution
A structural assembly for electric vehicles comprising a pair of opposed longitudinal outer rails, a plurality of cross beams, a pair of opposed longitudinal inner rails, at least one housing, and a plurality of bushings, which form a box structure to support the motor and reduce weight by eliminating the need for a separate subframe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a separate subframe is used to support the motor, then the motor support structure is simple and easy to manufacture, but the vehicle weight increases and structural integration is poor
Solution Approach 1:
The patent merges the motor support function with the existing vehicle frame structure by integrating cross beams and attachment structures directly into the frame rails, eliminating the need for a separate subframe. This combining approach reduces vehicle weight while maintaining motor support capability and improving structural integration.
2Adaptability or versatility
If attachment structures are integrated into the vehicle frame, then structural integration is improved and weight is reduced, but integration complexity and manufacturing difficulty increase
Solution Approach 1:
The patent designs cross beams and attachment structures that serve multiple functions: structural reinforcement of the vehicle frame, motor mounting support, and integration platform for electric modules. This multi-functionality approach reduces the need for separate components while managing integration complexity through standardized designs.
3Reliability
If cross beams and attachment structures are added to support electric modules, then motor support capability is improved, but the device complexity and number of components increase
Solution Approach 1:
The patent combines multiple support functions into integrated cross beam structures that are directly attached to the vehicle frame rails. These cross beams simultaneously provide structural reinforcement and motor mounting capability, reducing the total number of separate components while improving support reliability.
Data Source
AI summary
An electric vehicle includes a pair of opposed longitudinal outer rails, a plurality of cross beams, a pair of opposed longitudinal inner rails, a housing and a plurality of bushings. The cross beams extend in a transverse direction of the electric vehicle and include first and second cross beams secured to the pair of opposed longitudinal outer rails. The pair of opposed longitudinal inner rails are located inboard of the pair of opposed longitudinal outer rails and between the first and second cross beams. The pair of opposed longitudinal inner rails are secured to the first and second cross beams to form a box. The housing is connected to the box and is configured to be connected to the motor. The bushings are at least partially supported by the housing.