Offset Track Bar Geometry for Enlarged Electric Vehicle Axles
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Solution Overview
Problem
The integration of electric motors in electrified vehicles increases the size of the vehicle's axle, requiring adjustments to chassis system components to maintain lateral stiffness and control while accommodating the larger axle size.
Innovation Solution
A modified chassis system that includes a track bar with a hook portion and a linear displacement along a reference line, allowing it to modulate lateral movement and stiffness of the axle, while accommodating the varying diameter of the axle by extending around the transition between the first and second portions of the axle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the axle size is increased to accommodate the electric motor, then the power and propulsion capability are improved, but the lateral stiffness and lateral movement control of the axle deteriorate
Solution Approach 1:
The track bar is divided into three distinct segments: a first end for coupling to the axle, a second end for coupling to the frame, and a hook portion connecting these ends. This segmentation allows each portion to be optimized for its specific function while collectively maintaining lateral stiffness despite the larger axle size
Solution Approach 2:
The hook portion introduces an offset dimension perpendicular to the reference line that would otherwise connect the first and second ends directly. This offset creates a triangular geometry that provides lateral bracing, effectively adding a dimensional element that reinforces lateral stiffness without interfering with the enlarged axle diameter
2Power
If the axle size is increased to accommodate the electric motor, then the power and propulsion capability are improved, but the lateral movement control of the axle deteriorates
Solution Approach 1:
The track bar's segmented design with the hook portion allows the lateral control function to be separated from the primary load-bearing function. The hook portion specifically addresses lateral movement control by creating a triangular bracing geometry that constrains lateral displacement of the enlarged axle
Solution Approach 2:
The hook portion acts as an intermediary element that mediates between the enlarged axle and the frame connection. It provides a geometric constraint that limits lateral movement of the axle while allowing the track bar to accommodate the increased axle diameter without compromising control
3Adaptability or versatility
If the track bar is positioned to accommodate the larger axle diameter, then the integration with the electric motor and axle is improved, but the lateral stiffness and lateral movement control deteriorate
Solution Approach 1:
By introducing the offset dimension through the hook portion, the design achieves both goals: the first and second ends can be positioned to accommodate the larger axle diameter and electric motor integration, while the offset hook portion creates triangular bracing that maintains lateral stiffness
Solution Approach 2:
The segmentation of the track bar into distinct functional portions allows the ends to be optimized for integration with the enlarged axle and electric motor, while the hook portion independently provides lateral stiffness through its offset geometry
Data Source
AI summary
The chassis system may include a frame of the vehicle forming a base for the vehicle, an axle operably coupled to the frame, the axle having a first portion with a first diameter and a second portion with a second diameter, an electric motor operably coupled to the axle to propel the vehicle, one or more wheel assemblies operably coupled to the axle, and a track bar may be operably coupled to the axle via a first end and operably coupled to the frame via a second end. The second end may be linearly displaced from the first end along a reference line, and the track bar may include a hook portion defining an offset from the reference line, the offset extending away from the axle. The hook portion may extend around a transition between the first portion and the second portion of the axle.