Electric Motor Mounting Structure with Nested Cross Member
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Solution Overview
Problem
Existing electric motor mounting structures for vehicles lack sufficient stiffness to effectively support the torque generated by electric motors driving vehicle wheels, leading to potential instability and limitations in using high-output motors.
Innovation Solution
The electric motor mounting structure incorporates a combination of frame members with projecting mount members and threaded bolts, enhancing the bonding strength and stiffness by maximizing overlap and utilizing rubber members and collars to distribute stress, allowing for stable support of high-output electric motors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the electric motor is mounted on the cross member using conventional brackets and threaded bolts, then the structure is simple and easy to manufacture, but the stiffness and bonding strength are insufficient to support high-output motors
Solution Approach 1:
The mount member is inserted into a receiving hole formed in the cross member, creating a nested structure where the mount member is housed within the cross member's receiving hole. This nesting arrangement maximizes the overlap between the mount member and cross member, significantly enhancing bonding strength while maintaining structural integration.
Solution Approach 2:
The receiving hole is formed in the fore-aft direction of the cross member, allowing the mount member to project into the cross section of the cross member. This dimensional approach maximizes the bonding surface area and overlap between components, thereby increasing stiffness and bonding strength without proportionally increasing complexity.
2Strength
If the mount member projects into the cross section of the frame member, then the overlap and bonding strength are maximized, but the manufacturing precision requirements increase
Solution Approach 1:
The receiving hole is pre-formed in the cross member at the design stage with precise positioning. This preliminary action ensures that when the mount member is inserted, it automatically achieves the correct alignment and overlap, reducing the need for high-precision assembly operations and lowering overall manufacturing precision requirements.
Solution Approach 2:
The receiving hole acts as an intermediary structure that facilitates the connection between the cross member and mount member. By providing a pre-formed receiving hole, the system mediates the alignment and positioning requirements, making the assembly process more tolerant to manufacturing variations while still achieving maximum overlap and bonding strength.
3Power
If a high-output electric motor is used, then the power and performance are improved, but the moment and torque applied to the mounting structure increase, requiring higher stiffness
Solution Approach 1:
The mount member is nested within the receiving hole of the cross member, maximizing the overlap between the two components. This nested configuration significantly increases the bonding strength and stiffness of the mounting structure, enabling it to support the high moments and torques generated by high-output electric motors without excessive deflection or failure.
Solution Approach 2:
The mounting structure utilizes a composite arrangement of the cross member, receiving hole, and mount member working together as an integrated system. This composite structure combines the structural support of the cross member with the bonding interface of the mount member, creating a unified mounting system with enhanced stiffness and strength capability to handle high motor outputs.
Data Source
AI summary
The stiffness in supporting an electric motor is increased in an electric motor mounting structure for mounting an electric motor for driving the wheels on the vehicle body. In an electric motor mounting structure for mounting an electric motor (60) for driving a wheel on a vehicle body (1) formed by combining a plurality of frame members, the electric motor is mounted on one of the frame members (front middle cross member) (43) via a first mount member (front mount member) (71), the one frame member is provided with a receiving hole (101), and at least a part of the first mount member projects into the receiving hole.