Parametric Chassis Box-Module for Heavy Battery Storage

Solution Overview

Problem

The increasing need to incorporate heavy items like batteries or fuel cells in vehicles has led to longer wheelbases, resulting in heavier vehicles and challenges in achieving optimal structural rigidity and cost-effective suspension systems, as existing suspension configurations are not designed to efficiently manage these additional loads.

Innovation Solution

A parametric chassis system with four suspension elements, incorporating a lateral torsion bar and co-axial damper unit within a box-module, allowing for the central storage of heavy items and providing active-adaptive and asymmetrical-steer features, utilizing identical subsystems for high structural rigidity and cost-effective construction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If conventional suspension configurations are used to accommodate heavy items like batteries, then the wheelbase must be increased, but this results in heavier vehicle weight and reduced structural rigidity

Engineering Contradiction:

Improvecapacity for heavy itemsVSAvoidvehicle weight

Core Design Contradiction:

Quantity of substanceVSWeight of stationary object

Solution Approach 1:

The suspension module merges multiple functions into a single integrated unit: the torsion bar serves as both the spring element and a structural chassis member, the damper unit combines shock absorption with structural support, and the housing integrates mounting points for wheels, batteries, and other components. This consolidation eliminates the need for separate structural members, reducing overall vehicle weight while maintaining capacity for heavy items.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The suspension module is designed as a universal multi-functional unit that simultaneously provides suspension, structural support, mounting for heavy items (batteries, fuel cells), and chassis rigidity. The torsion bar and damper unit serve multiple purposes: suspension function, structural reinforcement, and mounting infrastructure, allowing the same component to fulfill several roles that traditionally required separate systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Stability of the object's composition

If conventional suspension configurations are used, then structural rigidity can be maintained, but the system becomes more complex and less cost-effective

Engineering Contradiction:

Improvestructural rigidityVSAvoidsuspension system complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The suspension module merges multiple functions into a single integrated unit: the torsion bar serves as both the spring element and a structural chassis member, the damper unit combines shock absorption with structural support, and the housing integrates mounting points for wheels, batteries, and other components. This consolidation eliminates the need for separate structural members, reducing overall vehicle weight while maintaining capacity for heavy items.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The suspension module is designed as a universal multi-functional unit that simultaneously provides suspension, structural support, mounting for heavy items (batteries, fuel cells), and chassis rigidity. The torsion bar and damper unit serve multiple purposes: suspension function, structural reinforcement, and mounting infrastructure, allowing the same component to fulfill several roles that traditionally required separate systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If identical suspension modules are used on all corners, then manufacturing cost is reduced and production is simplified, but adaptability to different loading conditions is limited

Engineering Contradiction:

Improvemanufacturing costVSAvoidadaptability to loading conditions

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The suspension module incorporates active-adaptive characteristics through the torsion bar and damper unit configuration that allows dynamic adjustment of suspension properties. The modular design enables the same basic unit to be configured for different corners of the vehicle, with the system as a whole adapting to varying loading conditions while maintaining manufacturing simplicity through component standardization.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

While the basic suspension module design is standardized for cost-effective manufacturing, the system allows for local variations in configuration to address specific corner requirements. The modular architecture enables differentiation in how modules are positioned or configured at different locations while maintaining the core design standards, balancing manufacturing efficiency with localized adaptability.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution enhances vehicle structural rigidity, reduces weight, and improves wheel compliance by using a multiplicity of identical suspension modules, enabling efficient storage of heavy items within the chassis while maintaining a compact and lightweight design, and allows for cost-effective production.

Implementation Method 1

lateral torsion bar...can be activated in an active-adaptive manner

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

co-axial damper unit housing a damper-fluid and having seals sealing the damper-fluid

Methodology Applied

Scientific EffectViscous damping: Viscous Damping

Data Source

PatentUS8083245B2Parametric chassis system for vehicles, comprising four suspension elements, incorporating a lateral torsion bar and co-axial damper unit, in a box-module, that allows central location of heavy items, such as batteries

Publication Date: 2011.12.27 HATZIKAKIDIS DIMITRIOS A

AI summary

A chassis system and a suspension module for vehicles having wheel subsystems incorporates a lateral torsion bar and a co-axial enveloping damper unit, featuring active-adaptive suspension characteristics. Pre-fabricated suspension modules are situated inside respective box-structures, connected via wheelbase and track members, allowing the storage of heavy elements (e.g., batteries or fuel-cells) at the chassis. The robust and self-carrying chassis is enhanced, using upper body members, in terms of structural rigidity, for a given wheelbase, achieving high impact-energy absorbtion. The suspension arms incorporate upper and lower members, articulation, connect internally or externally to the suspension module, and transmit drive and brake forces to the wheels. The suspension module, box-structure, torsion-bar/damper unit, drive and transmission unit, suspension arm and steer module, featuring asymmetrical steer characteristics, can be reproduced on each corner of the chassis, featuring electronic control without mechanical connection (steer by wire), constituting the chassis of the vehicle.