Modular EV Battery Floor Assembly for BEV and PHEV Packaging
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Solution Overview
Problem
The production and assembly of energy storage device floor assemblies for passenger cars with different drive concepts, such as electric (BEV) and hybrid (PHEV) drives, are complex and costly due to the need for various installation spaces and adaptations in the vehicle body structure.
Innovation Solution
A modular system for an energy storage device floor assembly that uses a uniform cross-design variant floor assembly, where the arrangement of components like energy storage devices and fuel tanks differs based on the drive type, allowing the same floor assembly to be used for both BEV and PHEV variants, with features like tunnels for exhaust systems and transverse braces for secure mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different floor assemblies are designed for BEV and PHEV variants, then component arrangement can be optimized for each drive type, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent applies universality by designing a single floor assembly that serves multiple functions across different drive variants. The floor assembly includes a common base structure with standardized fastening points that can accommodate both BEV energy storage devices and PHEV fuel tanks, eliminating the need for variant-specific floor designs while maintaining optimal component arrangement through configurable mounting positions.
Solution Approach 2:
The floor assembly is segmented into modular components including a base structure, fastening points, and configurable support elements. This segmentation allows the same floor assembly to be adapted to different drive variants by reconfiguring which fastening points are used and how components are arranged, rather than requiring completely different floor designs for BEV and PHEV variants.
2Productivity
If variant-specific body structure adaptations are made, then installation spaces can be optimized for each drive concept, but production cost and assembly difficulty increase
Solution Approach 1:
The floor assembly incorporates universal fastening points and standardized connection interfaces that work with the common body-in-white structure for both BEV and PHEV variants. This eliminates the need for variant-specific body structure adaptations while still allowing optimized installation spaces through configurable component positions on the standardized fastening points.
Solution Approach 2:
The floor assembly is designed with pre-configured fastening points and standardized interfaces during the development phase, allowing for easy adaptation to different drive variants without requiring complex body structure modifications. The preliminary design of universal mounting positions enables simple component installation for both BEV and PHEV variants using the same body-in-white structure.
3Ease of manufacture
If a uniform floor assembly is used for all variants, then manufacturing and assembly are simplified, but adaptability to different drive concepts is reduced
Solution Approach 1:
The floor assembly incorporates dynamic adaptability through configurable fastening points and modular support structures that can be adjusted based on the drive variant requirements. The same physical floor assembly can be adapted to different configurations by selecting different fastening points and arranging components differently, providing drive variant adaptability without sacrificing manufacturing simplicity.
Solution Approach 2:
The floor assembly applies local quality by providing specific structural features and fastening points in different locations to meet the particular requirements of BEV or PHEV variants. The common base structure maintains uniform manufacturing, while local variations in fastening point usage and component placement provide the necessary adaptability for different drive concepts.
Data Source
AI summary
A modular system is provided for an energy storage device floor assembly for an electrically operatable passenger car, including a cross-design variant floor assembly which has a main floor and a rear floor. In a first design variant for a passenger car with a solely electric drive, an energy storage device is provided which extends both below the main floor as well as the rear floor, and in a second design variant for a passenger car with a hybrid drive, an energy storage device, which extends solely below the main floor, and a fuel tank, which extends below the rear floor, are provided. A method is disclosed for producing such an energy storage device floor assembly.