Electric Vehicle Power Unit Suspension Frame Design
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Solution Overview
Problem
Conventional suspension structures for electric vehicles fail to efficiently absorb loads in the vertical, width, and front-back directions, leading to vibration propagation and potential breakage of high voltage cables and motor electrode terminals due to inadequate load distribution and vibration absorption.
Innovation Solution
A power unit suspension structure with a frame that suspends the power unit from the vehicle body, utilizing a shared shaft between the motor and motor speed reducer, with circular mount rubbers and motor-side mount brackets to absorb loads and reduce vibration, and an L-shaped frame configuration to enhance rigidity and prevent contact with surrounding structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional frame structure is used to suspend the power unit, then the power unit can be supported, but loads in vertical, width, and front-back directions cannot be efficiently absorbed, causing vibration propagation
Solution Approach 1:
The frame is divided into multiple functional portions: front portion extending in vehicle width direction, side portions extending in front-back direction, rear portion with inclined section, and lower portion. Each portion is optimized to absorb specific load directions, enabling efficient multi-directional load absorption and reducing vibration propagation to the vehicle body.
Solution Approach 2:
The frame transitions from a conventional planar structure to a three-dimensional configuration with portions extending in multiple directions (width direction, front-back direction, and inclined rear portion). This spatial arrangement allows the frame to absorb loads from vertical, lateral, and longitudinal directions simultaneously, improving overall load absorption efficiency.
2Ease of manufacture
If the power unit is suspended with a simple frame structure, then installation is straightforward, but high voltage cables and motor electrode terminals may break due to inadequate load distribution
Solution Approach 1:
The frame incorporates a rear portion positioned in the upper part of the vehicle that specifically protects the high voltage cable and motor electrode terminal areas. This localized structural enhancement provides targeted protection for vulnerable components while maintaining overall manufacturing simplicity, preventing cable breakage during lateral impacts without complicating the entire frame structure.
3Volume of moving object
If the power unit is positioned close to surrounding structures to save space, then vehicle packaging is improved, but contact between power unit and structures occurs during lateral impacts
Solution Approach 1:
The frame acts as an intermediary protective structure between the power unit and surrounding vehicle structures. The side portions extending in the front-back direction and the rear portion create a protective envelope around the power unit, absorbing lateral impact loads and preventing direct contact between the power unit and surrounding structures during side collisions.
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
Effectively absorbs loads and vibrations, reducing the risk of breakage and noise, while maintaining the integrity of high voltage components by distributing loads efficiently and increasing the durability of suspension components.
Implementation Method 1
a circular mount rubber having a center on an extending line of the shaft of the motor, and a motor-side mount bracket
Data Source
AI summary
A power unit 4 is mounted in a rear part of a vehicle, a shaft C shared by a motor 2 and a motor speed reducer 3 is disposed in a vehicle width direction, and a sub-frame 8 is provided around the power unit 4, a front cross frame 11 is disposed over a front portion of the power unit 4 in a front view of the vehicle and disposed in parallel with the shaft C of the motor 2, a rear cross frame 12 is disposed over a side portion of the power unit 4 in a side view of the vehicle, and left and right side portions of the power unit 4 are suspended from a vehicle body via suspension brackets 13 and 14 provided on side frames 9 and 10, circular mount rubbers 15 and 16, and motor-side mount brackets 17 and 18.