Modular EV Conversion Support Structure for Faster Vehicle Retrofit
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Solution Overview
Problem
Current methods for converting internal combustion engine vehicles to electric vehicles are inefficient, as they often require individual adaptation of electrical drive components and lack standardization, leading to increased time and financial costs, and limiting the conversion of vehicles with lower residual useful life.
Innovation Solution
A modular kit system comprising a mechanical support structure with a connection interface and electrical equipping components, allowing for the conversion of internal combustion engine vehicles to electric traction drives by selecting and attaching specific components to form different drive variants, thereby standardizing the conversion process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If individual adaptation of electrical drive components is performed for each vehicle, then the conversion can be tailored to specific vehicle requirements, but the conversion time and costs increase significantly
Solution Approach 1:
The conversion system is divided into modular components: a standardized support structure and separate equipping components (electrical machine, power electronics, control units). This segmentation allows the support structure to be reused across multiple vehicles while enabling customization through different component combinations, thereby reducing conversion time while maintaining adaptability.
Solution Approach 2:
The support structure is designed as a universal platform that can accommodate various equipping components and adapt to different vehicle types. The standardized connection interfaces and mounting systems enable the same support structure to serve multiple conversion scenarios, reducing the need for vehicle-specific adaptations while preserving customization capabilities.
2Adaptability or versatility
If individual adaptation of electrical drive components is performed for each vehicle, then the conversion can be tailored to specific vehicle requirements, but the financial expenditure increases
Solution Approach 1:
By segmenting the conversion system into a reusable support structure and interchangeable equipping components, the patent enables standardized manufacturing processes. The support structure can be produced once and reused across multiple conversions, while equipping components can be manufactured using standardized processes, significantly reducing per-vehicle conversion costs while maintaining customization options.
Solution Approach 2:
The support structure is designed to be recovered and reused across multiple vehicle conversions. Instead of creating a completely new conversion system for each vehicle, the support structure is removed from one vehicle, adapted if necessary, and installed in another, thereby recovering the investment and reducing overall conversion costs while maintaining adaptability.
3Reliability
If individual approval by technical inspection service is required for each converted vehicle, then safety and compliance can be ensured, but the conversion process becomes time-consuming and expensive
Solution Approach 1:
The standardized support structure and equipping components are designed to meet predefined safety and compliance standards. This universality allows technical inspection services to approve the standardized components once, and this approval can be extended to multiple vehicles using the same components, reducing the time and cost of individual approvals while maintaining reliability through consistent standardized designs.
4Duration of action of stationary object
If older vehicles are converted to electric drives, then the useful life of vehicles can be extended, but the residual useful life upon conversion is lower
Solution Approach 1:
The modular conversion system allows for precise matching of equipping components to the specific condition and requirements of older vehicles. The support structure can be adapted to accommodate the space and mounting constraints of older vehicle platforms, while equipping components can be selected based on the vehicle's remaining useful life requirements, enabling reliable conversions of older vehicles without compromising their extended serviceability.
Data Source
AI summary
A modular kit system (14) for converting a traction drive (40) of a motor vehicle (10) from a drive having an internal combustion engine (11) to an electric traction drive (40). The kit (14) includes a mechanical support structure (15) having a mechanical connection interface (33) for fastening the support structure (15) in an engine compartment (12) of the motor vehicle (10) in place of the internal combustion engine (11), and electrical equipping components (16) for equipping the support structure (15), wherein the support structure (15) has equipment places (28) each for fastening one of the equipping components (16) in and/or on the support structure (15), and each equipment place corresponds, with respect to a form and/or a fastening device, with a form and/or a fastening device of a fastening region of the associated equipping component (16) for which the equipment place is provided.