Front-End Accessory Frame for Pre-Assembled EV Integration
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Solution Overview
Problem
There is a need for improved systems and strategies to equip vehicles with electric storage, auxiliary, and propulsion assemblies that allow multiple components to be mounted in a vehicle's front end compartment simultaneously, requiring a shared frame that fits within the stock chassis and can be conveniently mounted with minimal connection steps.
Innovation Solution
A front end accessory component assembly comprising a frame that supports multiple vehicle accessories, allowing pre-assembly away from the vehicle chassis, with electrical and thermal management components connected in a pre-installed configuration, and a modular system that integrates with the vehicle's chassis with minimal additional connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple vehicle accessories are mounted separately to the chassis, then each component can be individually positioned, but the assembly process becomes complex and time-consuming
Solution Approach 1:
Multiple vehicle accessories (battery assembly, charging system, thermal management components) are merged into a single integrated front end accessory component assembly that mounts to the chassis as one unit, reducing the number of separate mounting operations and connection steps required
Solution Approach 2:
The accessories are pre-assembled and pre-configured into a complete assembly unit before being mounted to the chassis, allowing electrical connections and thermal management pathways to be established in advance, so that only a single mounting operation is needed during vehicle assembly
2Ease of manufacture
If a shared frame is introduced to support multiple components, then assembly is simplified, but the frame must fit within the stock chassis constraints
Solution Approach 1:
The shared frame structure is designed to perform multiple functions simultaneously: it provides structural support for multiple accessories, serves as a mounting platform for electrical connections, acts as a thermal management conduit pathway, and integrates with the vehicle chassis, thereby consolidating several functions into a single component that maximizes space utilization
3Productivity
If electrical and thermal management components are pre-configured, then integration time is reduced, but the pre-assembly process adds manufacturing complexity
Solution Approach 1:
Electrical connections between accessories and thermal management pathways are established during the pre-assembly process, allowing these complex connection tasks to be performed in a controlled manufacturing environment where precision tools and fixtures are available, rather than during vehicle assembly where time and space are constrained
Data Source
AI summary
An accessory component assembly is provided that includes a frame, a first vehicle accessory, and a second vehicle accessory. The frame is configured to support vehicle accessories. The first vehicle accessory is mounted to the frame. The second vehicle accessory is mounted to the frame. The frame is configured to simultaneously couple the first vehicle accessory and the second vehicle accessory to a chassis of a vehicle such that the accessory component assembly can be functionally coupled to at least two other vehicle sub-systems.