K-Shaped Frame Support Assembly for Impact Force Distribution
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Solution Overview
Problem
Existing vehicle propulsion systems face challenges in maintaining rigidity and reducing deformation, particularly around the battery compartment, during frontal impacts, as existing frame structures are prone to compression stress and deformation.
Innovation Solution
The use of a frame assembly comprising elongated frame rails, crossbeams, and support members that transmit force applied during impacts, reducing compression stress on the frame rails and minimizing deformation by distributing the force throughout the vehicle components, including a K-shaped configuration of support members and crossbeams that provide additional rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional frame structure is used, then the device complexity is low, but the rigidity and resistance to deformation during impacts is insufficient
Solution Approach 1:
The frame structure is segmented into multiple components including frame rails, crossbeams, and support members arranged in a K-shaped configuration. This segmentation allows each component to specifically address different stress patterns during impacts, with the crossbeams and support members working together to distribute and manage compression stresses effectively throughout the frame structure.
2Ease of manufacture
If the frame structure is simplified, then the manufacturing cost is reduced, but the ability to transmit and distribute impact forces is compromised
Solution Approach 1:
The frame assembly merges multiple structural elements (frame rails, crossbeams, and support members) into an integrated K-shaped configuration that functions as a unified force distribution system. This merging allows impact forces to be transmitted and distributed through the combined structure, achieving effective force management while maintaining manufacturability through standardized component assembly.
3Reliability
If additional support members are added to reduce deformation, then the structural integrity is improved, but the weight of the frame increases
Solution Approach 1:
The frame structure implements local quality by concentrating support members and crossbeams in specific locations where compression stresses are most pronounced during frontal impacts. The K-shaped configuration places structural reinforcement locally at critical stress points rather than uniformly throughout the entire frame, achieving improved structural integrity while minimizing unnecessary weight addition.
Data Source
AI summary
An assembly includes a first frame rail and a second frame rail elongated along a longitudinal axis and spaced from each other along a lateral axis. The assembly includes a crossbeam extending along the lateral axis and fixed under the first frame rail and the second frame rail. The assembly includes a first support member extending transversely from the crossbeam to a first end fixed to the first frame rail. The assembly includes a second support member extending transversely from the crossbeam to a second end fixed to the second frame rail.