Integrated Motor Housing Node for Load-Bearing EV Structures
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Solution Overview
Problem
Existing electric motors in electric cars are attached to the load-bearing structure using separate components like brackets and bolts, which increases weight and assembly complexity, and do not contribute to load bearing or crash protection.
Innovation Solution
Integrate the electric motor housing with the load-bearing structure, using a 3D printed multi-functional node that serves as both a motor housing and a load-bearing component, transferring loads through separate paths and eliminating the need for additional attachment mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electric motors are attached to the load bearing structure using separate components like brackets and bolts, then the motor is securely mounted, but the vehicle weight increases and assembly complexity increases
Solution Approach 1:
The motor housing is merged with the load bearing structure into a single integrated component. The housing itself is designed with load-bearing capabilities, eliminating the need for separate mounting brackets and bolts. This consolidation reduces the number of parts and overall weight while maintaining secure motor attachment to the vehicle chassis.
Solution Approach 2:
The motor housing serves multiple functions simultaneously: it protects the motor components, provides structural support, and acts as a load-bearing element for the vehicle. This multi-functionality eliminates the need for dedicated mounting components, reducing weight and simplifying the overall structure.
2Reliability
If electric motors are attached to the load bearing structure using separate components like brackets and bolts, then the motor is securely mounted, but the assembly process becomes more complex
Solution Approach 1:
The motor housing and load bearing structure are combined into a single integrated component, reducing the number of assembly steps. Instead of separately attaching brackets and bolts, the motor is directly mounted to the integrated housing-structure assembly, simplifying the assembly process while maintaining secure mounting.
Solution Approach 2:
The integrated housing serves multiple functions including motor protection, structural support, and load bearing. This multi-functionality reduces the number of separate components that need to be assembled, thereby reducing assembly complexity while ensuring secure motor mounting.
3Reliability
If the motor housing serves only as a protective cover, then the motor components are protected, but additional load bearing components are needed
Solution Approach 1:
The motor housing is designed to simultaneously protect motor components and bear vehicle loads. By integrating load-bearing structural elements directly into the housing design, the need for separate mounting components is eliminated, reducing overall structural complexity while maintaining both protection and load-bearing capabilities.
4Weight of moving object
If the motor housing is integrated with the load bearing structure, then vehicle weight is reduced, but the housing must withstand higher stresses
Solution Approach 1:
The motor housing is merged with the load bearing structure, creating a unified component that leverages the strength of both elements. The integrated design allows loads to be distributed through the housing-structure combination, reducing peak stresses while eliminating the weight of separate mounting components.
Solution Approach 2:
The integrated housing-structure assembly may utilize composite material constructions or optimized material distributions to achieve the required strength-to-weight ratio. The design can incorporate different materials or material densities in different regions to withstand higher stresses while minimizing overall weight.
Data Source
AI summary
Integrated vehicle structures are provided herein. An integrated vehicle structure can include an enclosure portion configured to house an electric motor and a plurality of extended portions extending from the enclosure portion. The enclosure portion and the plurality of extended portions can be load-bearing and configured to bear vehicle loads. The extended portions of the integrated vehicle structures can include a connection portion configured to connect with another load-bearing structure to at least receive or transmit loads. The plurality of extended portions can be configured to transfer vehicle loads along physically separate paths. A portion of the enclosure portion can define an opening configured to allow a drive shaft to connect the electric motor to a wheel. The enclosure portion can be configured with an opening for allowing the installation and removal of the electric motor.