Modular Chassis Structure for Alternative Powertrain Integration
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Solution Overview
Problem
Retrofitting existing vehicle chassis designed for internal combustion engines to accommodate alternative or hybrid powertrains is limited by design and size constraints, as they need to accommodate battery packs, fuel cells, and additional components, which is not efficiently supported by traditional chassis structures.
Innovation Solution
A modular chassis design featuring modular packs that can be coupled together to form a scalable structure, supporting various vehicle subsystems such as battery packs, thermal management systems, and fuel cell systems, with adjustable fastening assemblies and structural elements like side tie plates and subframes to accommodate different vehicle configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional chassis structures are used, then structural simplicity is maintained, but adaptability to alternative powertrains deteriorates
Solution Approach 1:
The chassis is divided into modular subframes (front subframe, rear subframe) and modular packs that can be independently configured. Each modular pack contains standardized mounting interfaces, allowing different powertrain components to be installed in different positions without redesigning the entire chassis structure.
Solution Approach 2:
The modular packs are designed with universal mounting interfaces and standardized dimensions that can accommodate various powertrain types (battery packs, fuel cells, hybrid systems). The same basic modular structure serves multiple functions by simply changing the components installed within the standardized bays.
2Adaptability or versatility
If existing chassis are retrofitted, then implementation time is reduced, but design flexibility is limited
Solution Approach 1:
The modular subframes and packs are pre-designed with standardized interfaces and mounting points during the development phase. This preliminary structuring allows rapid assembly and configuration when implementing different powertrain designs, eliminating the need for time-consuming custom fabrication or major modifications.
3Adaptability or versatility
If modular packs are added to accommodate powertrain components, then adaptability is improved, but structural complexity increases
Solution Approach 1:
Multiple functional components (battery modules, structural elements, mounting brackets, thermal management components) are merged into integrated modular packs. Each modular pack combines several functions into a single standardized unit, reducing the total number of separate components while maintaining configuration flexibility.
Data Source
AI summary
A modular chassis with one or more modular packs configured to couple to an adjacent modular pack and/or subframe to form a modular chassis for a vehicle. Each of the one or more modular packs may be configured to contain and carry or otherwise support a subsystem, a component, or a component of a subsystem for operation of the vehicle. One or more modular packs within a modular chassis may be empty and serve only a support or structural function for the modular chassis.