Modular Extruded EV Chassis With T-Slot Sealed Electronics Housing
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Solution Overview
Problem
Traditional chassis structures for electric vehicles are inflexible, costly, and lack waterproof and dustproof solutions for electronics, limiting design changes and increasing manufacturing time and cost, while also being heavy and prone to failure due to inadequate sealing.
Innovation Solution
A versatile extruded profile chassis made of light metal with T-slot profiles that allows for easy attachment and detachment of components without welding, providing a waterproof and dustproof enclosure for electronics and enabling flexible design changes and length adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional chassis structures are used, then structural strength and stability are ensured, but design flexibility and adaptability are reduced
Solution Approach 1:
The chassis is divided into modular extruded profile sections that can be independently manufactured and assembled. Each section contains standardized T-slot profiles that allow for flexible configuration without redesigning the entire chassis structure, enabling easy adaptation to different vehicle requirements.
Solution Approach 2:
The extruded profiles are designed with universal T-slot configurations that can accommodate multiple types of attachments and components. The same profile design serves various functions including structural support, mounting surfaces, and adjustment mechanisms across different vehicle configurations.
2Productivity
If traditional chassis structures are used, then structural stability is maintained, but manufacturing cost and time increase
Solution Approach 1:
The extruded profiles are pre-manufactured with integrated T-slot features and attachment points during the extrusion process itself, rather than adding these features later through secondary operations. This preliminary incorporation of mounting capabilities eliminates subsequent machining steps and reduces overall manufacturing time and cost.
Solution Approach 2:
The extrusion process allows for rapid parameter changes in profile geometry, length, and slot configurations by adjusting extrusion dies and parameters. This enables cost-effective production of customized chassis sections without requiring expensive retooling or re machining operations.
3Strength
If extruded profiles are dimensioned to suit stiffness-critical sections, then structural strength is improved, but excess material increases weight and requires additional machining
Solution Approach 1:
The T-slot profiles are designed with varying wall thicknesses and geometric properties at different locations along the extrusion. Critical sections have enhanced thickness and reinforcement for maximum stiffness, while non-critical sections use minimal material necessary for structural integrity, eliminating unnecessary weight throughout the entire chassis.
Solution Approach 2:
The modular extruded profile system allows for dynamic adjustment of structural characteristics by selecting different profile sections and configurations for specific applications. This enables optimization of material distribution to match actual load requirements rather than using uniform over-engineered sections throughout.
4Reliability
If conventional metallic chassis structures are used, then structural integrity is ensured, but waterproof and dustproof sealing is inadequate
Solution Approach 1:
The T-slot profiles incorporate integrated sealing channels and grooves that accommodate flexible sealing elements such as gaskets and membranes. These sealing features create waterproof and dustproof barriers between chassis sections and protect electronic components mounted within the profile cavities from environmental contaminants.
Data Source
AI summary
An extruded chassis structure for an electric platform vehicle is provided. The chassis structure includes a top elongated wall arranged in a spaced-apart relationship with a bottom elongated wall and a first elongated side wall arranged in a spaced-apart relationship with a second elongated side wall. The top wall, the bottom wall, and the first and second side walls are interconnected using at least four T-slot profiles, each located at a corner of the extruded chassis structure. The chassis structure also includes a front-end cap, and a rear-end cap forming an enclosed space there inside. Each of the T-slot profiles includes tracks to facilitate mounting vehicle-related components and vehicle-related attachments to the extruded chassis structure.