Front Beam Axle Power Unit Layout for 4WD Battery Packaging
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Solution Overview
Problem
Existing vehicle powertrains and structures struggle to meet packaging and performance design objectives for vehicles with higher towing capacity and electrification, particularly in unibody and body-on-frame configurations.
Innovation Solution
A vehicle system featuring a steerable front beam axle, rear beam axle, continuous traction battery between frame rails, and a power unit that supplies propulsive effort to front wheels, allowing for compact packaging and increased charge storage capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional powertrain layout is used in a body-on-frame vehicle, then the vehicle structure is simple and robust, but the packaging efficiency is poor and towing capacity is limited
Solution Approach 1:
The patent positions the traction battery vertically between the frame rails rather than longitudinally, utilizing the vertical dimension to accommodate the battery pack. This dimensional change allows the battery to fit within the constrained space of the body-on-frame structure without extending beyond the vehicle's outer dimensions, thereby improving packaging efficiency while maintaining structural simplicity.
Solution Approach 2:
The frame rails serve multiple functions: they provide structural support for the body-on-frame construction, act as mounting points for the traction battery, and define the boundaries for component packaging. This multi-functionality reduces the need for additional structural elements, maintaining structural simplicity while enabling enhanced towing capacity through proper component integration.
2Quantity of substance
If a large traction battery is installed to provide extended electric power, then the charge storage capacity increases, but the packaging space is constrained
Solution Approach 1:
The traction battery is oriented vertically between the frame rails, utilizing the height dimension of the vehicle structure. This vertical positioning allows the battery to achieve sufficient charge storage capacity without extending longitudinally or laterally, thereby maximizing the use of available packaging space within the body-on-frame architecture.
Solution Approach 2:
The traction battery is nested within the space defined by the frame rails, fitting into the structural envelope of the vehicle chassis. This nesting approach allows the battery to be integrated into the existing structure without requiring additional external space, thereby increasing charge storage capacity within constrained packaging volume.
3Adaptability or versatility
If the power unit is positioned to supply propulsive effort to front wheels, then four-wheel drive capability is achieved, but steering components may interfere with the power unit
Solution Approach 1:
The power unit is segmented into distinct components (internal combustion engine, electric machine, transmission elements) that are independently positioned and mounted. This segmentation allows each component to be optimally located to avoid interference with steering mechanisms while maintaining the functional integration needed for four-wheel drive operation.
Solution Approach 2:
Different portions of the power unit are positioned in different locations within the front axle assembly. The electric machine and transmission components are locally positioned to avoid steering component interference zones, while the internal combustion engine is positioned in a separate zone. This localized optimization of component placement enables four-wheel drive capability without compromising steering functionality.
Data Source
AI summary
Methods and systems for configuring a four-wheel drive high gross weight vehicle are presented. In one non-limiting example, a traction battery covers a lateral expanse between a first frame rail and a second frame rail, thereby providing higher storage capacity for the traction battery even though the vehicle is configured for four-wheel drive.