Electric Front-End Structure With Motor Catching Support
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Solution Overview
Problem
The challenge in electric vehicles with high-torque electric traction motors is the potential for increased vehicle impulse index (VPI) and deformation of the instrument panel during frontal impacts, necessitating a new motor suspension and support system to manage motor displacement and protect electronic components.
Innovation Solution
A front-end structure with longitudinal members and a support unit that fastens the electric traction motor to a crossmember, featuring a catching section to limit motor displacement and absorb impact forces without additional weight or components, using the support unit to secure the motor and inhibit slippage during impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the electric traction motor is rigidly fastened to the support unit, then the motor stability is improved, but the vehicle impulse index increases and occupant protection performance decreases during frontal impact
Solution Approach 1:
The fastening connection between the electric traction motor and support unit is designed to transition from a rigid static connection to a dynamic connection that allows controlled movement during impact. The motor can move relative to the support unit along a predetermined movement path, transforming the rigid fastening into a dynamic system that adapts to impact conditions.
Solution Approach 2:
The system pre-establishes a controlled movement capability and energy absorption mechanism before impact occurs. The motor suspension geometry and fastening design are configured in advance to allow the motor to move and absorb impact energy, cushioning the effect on the instrument panel and occupants during frontal collision.
2Volume of moving object
If the front section of the motor vehicle is shortened to create more space, then the vehicle design flexibility is improved, but the instrument panel becomes more vulnerable to deformation during impact
Solution Approach 1:
The electric traction motor and its suspension system serve as an intermediary element between the front-end structure and the instrument panel. During impact, the motor moves relative to the support unit, absorbing and distributing impact forces before they reach the instrument panel, thereby protecting the panel while allowing compact vehicle design.
Solution Approach 2:
The instrument panel is effectively decoupled from the direct impact path by extracting it from the load path through the motor suspension design. The motor's controlled movement and the support unit's catching section remove the instrument panel from the primary impact force transmission path.
3Power
If longer lever arms are used to increase motor torque, then the motor's torque capability is improved, but the motor's center of gravity displacement requires new suspension geometry
Solution Approach 1:
The support unit serves multiple functions: it provides the motor suspension mounting, defines the motor's center of gravity position, allows controlled motor movement during impact, and catches the motor at the end of the movement path. This multi-functional design simplifies the overall suspension geometry while achieving the required torque capability.
Solution Approach 2:
The motor suspension geometry is merged with the impact protection mechanism. The same support unit and fastening connection that provide motor mounting and torque support also enable controlled motor movement and impact energy absorption, combining structural support and safety functions into a single integrated system.
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
The solution enhances VPI by controlling motor displacement, reducing deformation, and protecting electronic components, while maintaining the vehicle's structural integrity and design space without adding weight or complexity.
Implementation Method 1
The longitudinal members (2, 3) are set up to deform plastically in the event of a certain type of frontal impact
Implementation Method 2
the support unit (4) has at least one catching section (10) which is set up to catch the rear-side fastening section (9) of the electric traction motor (7)
Data Source
AI summary
A front-end structure for a motor vehicle with electric front-wheel drive. The front-end structure includes at least two longitudinal members, at least one support unit, and at least one electric traction motor. The longitudinal members extending in a vehicle longitudinal direction and arranged at a lateral distance from each other. The support unit is fastened to the longitudinal members. The electric traction motor is fastened to a front-side crossmember that extends in a vehicle transverse direction and is fastened to the longitudinal members. The electric traction motor has at least one rear-side fastening section, which the electric traction motor is fastened to the support unit at the rear. The support unit has at least one section arranged to be offset relative to the rear-side fastening section.