Intermediate Frame Layout for Integrated Electric Work Vehicle Chassis
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Solution Overview
Problem
Existing electric vehicles lack an efficient and integrated structural solution for housing and protecting electrical and hydraulic components, which can lead to increased complexity, weight, and reduced performance.
Innovation Solution
The design incorporates an intermediate frame with curved wall portions and openings to house electrical converters, pumps, hydraulic manifolds, and other components, providing a structured and protected environment while allowing for efficient passage of cables and coolant lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical and hydraulic components are housed separately without integration, then component protection is reduced, but device complexity increases
Solution Approach 1:
The patent combines electrical components (converters, cables) and hydraulic components (pumps, manifolds) into a single integrated intermediate frame structure. This merging provides unified protection for all components while reducing the number of separate housings and mounting structures needed, thereby decreasing overall device complexity while improving component protection.
Solution Approach 2:
The intermediate frame serves multiple functions simultaneously: it provides structural support for the vehicle, houses and protects electrical converters and cables, accommodates hydraulic pumps and manifolds, and facilitates passage of coolant lines. This multi-functionality reduces the need for separate protective structures for each component type.
2Weight of moving object
If components are housed in a compact integrated structure, then weight is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The intermediate frame is designed as a segmented structure with distinct zones for electrical components, hydraulic components, and coolant passage routing. This segmentation allows each zone to be manufactured and assembled separately with standard tolerances, then combined into the final integrated structure, reducing overall manufacturing precision requirements while maintaining compact weight-saving design.
3Strength
If wall portions are curved for structural optimization, then strength is improved, but manufacturing complexity increases
Solution Approach 1:
The intermediate frame incorporates curved wall portions that provide structural strength and rigidity while distributing stress more effectively than flat walls. The curvature is designed to follow standard fabrication capabilities, balancing strength optimization with manufacturability through conventional forming processes.
4Ease of operation
If openings are added for cable and coolant line passage, then ease of operation is improved, but structural integrity is reduced
Solution Approach 1:
The intermediate frame features locally optimized openings strategically positioned for cable and coolant line passage. These openings are concentrated in specific areas where structural loads are minimal, while other regions maintain solid wall structures for strength. The local quality approach allows easy routing of cables and coolant lines without compromising overall frame integrity.
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
An electric work vehicle (1) includes a chassis, a battery housing (8) supported by the chassis, and a rear axle. The chassis includes an intermediate frame (6) attached to a rear portion of the battery housing (8). The intermediate frame (6) is located between the battery housing (8) and the rear axle in a front-rear direction of the electric work vehicle (1). The intermediate frame (6) includes a plurality of wall portions (62) that define an interior space.