Electric Vehicle Subframe with Modular Castings and Cross-Car Extrusions
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Solution Overview
Problem
Existing automotive subframes for electric vehicles lack a modular and robust design capable of housing multiple electric motors and supporting advanced suspension and steering systems, which limits their safety, vibration reduction, and handling performance.
Innovation Solution
A rear subframe design featuring two castings coupled by longitudinal and lateral cross-car extrusions, with a roll bar and removable braces to secure motors, integrated motor mounts, and a rear steering actuator, allowing for the housing of one or two electric motors and supporting a suspension system with semi-trailing arms and air springs, enhancing structural integrity and ease of installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional subframe design is used, then the structure is simple, but it cannot house multiple electric motors and lacks robustness for advanced suspension systems
Solution Approach 1:
The subframe is divided into multiple castings (front subframe casting, rear subframe casting) that are spaced apart and coupled by cross-car extrusions. This segmentation allows the subframe to accommodate multiple electric motors and suspension components while maintaining structural integrity and managing complexity through modular construction.
Solution Approach 2:
The subframe design integrates multiple functions into a single structural system: it houses electric motors, supports suspension components (control arms, trailing arms), accommodates steering mechanisms, and provides motor mounting points. This multi-functionality increases adaptability without proportionally increasing complexity.
2Reliability
If the subframe is designed to protect motors during collisions, then safety is improved, but the structural complexity increases
Solution Approach 1:
The subframe uses separate front and rear castings coupled by cross-car extrusions, creating a modular structure that can be optimized for collision protection in different zones while maintaining overall structural integrity. Each casting can be independently designed for specific protection requirements.
Solution Approach 2:
The subframe structure is designed with inherent collision protection capabilities through its rigid casting construction and strategic placement of cross-car extrusions that act as reinforcement elements. The motor receiving volume is bounded by multiple structural elements that provide protective enclosures before collisions occur.
3Ease of operation
If removable braces are used to secure motors, then ease of installation is improved, but the structural complexity increases
Solution Approach 1:
The subframe incorporates removable braces that can be installed or removed as needed for motor installation and maintenance. This dynamic configuration allows the structure to transition between different states (with or without motors) while maintaining structural integrity when components are present.
Solution Approach 2:
The subframe is designed with pre-configured mounting points, motor mounts, and brace attachment locations that are prepared in advance during manufacturing. This preliminary preparation simplifies the installation process by eliminating the need for custom fabrication or complex alignment procedures during assembly.
Data Source
AI summary
Disclosed herein is a rear subframe and suspension system. The subframe may be configured to accommodate one or two electric motors for propelling an automobile. The subframe may be configured such that the motor(s) is inserted through the front end of the subframe. The subframe may substantially surround the motor. Braces may be the coupled to the subframe to secure the motor within the subframe. The subframe may further include built-in motor mounts. An independent rear suspension system and rear steering system may also be coupled to the subframe.