Powertrain Mount Assembly With Shear-Off Coupling Arms for Crash Space
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Solution Overview
Problem
Vehicle crashes, particularly in electric vehicles with shorter front overhangs, pose a safety risk due to limited deformation space and potential intrusion of components into the cabin and energy storage systems.
Innovation Solution
A powertrain assembly with a drive shaft perpendicular to the vehicle's driving direction, featuring coupling arms and mounts that disconnect upon collision, allowing the powertrain unit to shift and rotate, thereby increasing deformation space and minimizing intrusions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the powertrain unit is rigidly fixed to the vehicle body, then the structural stability is improved, but the deformation space in the front overhang is reduced during collision
Solution Approach 1:
The coupling arm is designed as a dynamic connection element that transitions from a rigid state during normal operation to a disconnected state during collision. The fixing element is configured to shear off under collision forces, allowing the powertrain unit to move forward and create deformation space, thus resolving the contradiction between structural stability and deformation space requirements.
2Length of moving object
If the front overhang is shortened to improve vehicle design, then the vehicle dimensions are optimized, but the deformation space during collision is reduced
Solution Approach 1:
The connection between the powertrain unit and vehicle body is segmented into modular components (coupling arm, fixing element, mount) that can independently respond to collision forces. This segmentation allows the fixing element to shear off while other components remain intact, enabling the powertrain unit to move forward and create deformation space even in vehicles with shortened front overhangs.
3Reliability
If the powertrain unit is securely mounted, then the reliability of power transmission is improved, but the intrusion risk into the cabin during collision increases
Solution Approach 1:
The coupling arm and fixing element are pre-configured to fail in a controlled manner during collision. The fixing element is designed to shear off at a predetermined location, and the coupling arm is designed to disconnect from the mount, allowing the powertrain unit to move forward before potentially intruding into the cabin. This preliminary configuration ensures that the connection maintains reliability during normal operation but fails safely during collision.
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
The solution enhances vehicle safety by extending the stopping distance and preventing components from invading the cabin and energy storage systems during collisions, reducing crash forces and intrusions.
Implementation Method 1
The first fixing element is configured to be sheared off from the first coupling arm to at least partially disconnect the powertrain unit from the first coupling arms after the clash of the first coupling arm into the first mount
Implementation Method 2
The first coupling arm is configured to clash into the first mount in case of a vehicle collision
Data Source
AI summary
A powertrain assembly including a powertrain unit with a drive shaft, at least a first mount and at least a first coupling arm, arranged to direct the drive shaft substantially perpendicular to a driving direction of the vehicle. The first mount is arranged substantially perpendicular to the drive shaft. The first coupling arm is arranged between a first end side of the powertrain unit and the first mount and is connected to the powertrain unit by at least a first fixing element to hold the powertrain unit in an initial position. The first coupling arm is configured to clash into the first mount in case of a vehicle collision. The first fixing element is configured to be sheared off from the first coupling arm to at least partially disconnect the powertrain unit from the first coupling arms after the clash of the first coupling arm into the first mount.