Rear Axle Battery Substructure With Crash Load Transfer Assembly
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Solution Overview
Problem
Vehicle substructures for semi-electrically driven vehicles with steerable rear wheels face challenges in ensuring high crash safety, protecting batteries, reducing weight, and facilitating easy assembly and maintenance, while also requiring efficient space utilization and accessible design for rear axle components.
Innovation Solution
A vehicle substructure featuring a chassis auxiliary frame connected to a body via a mounting carrier that allows pre-mounting assembly of the battery system and chassis as a unit, with a trapezoidal mounting carrier providing load transfer in crash events and protecting the battery system during installation and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the battery system and chassis auxiliary frame are separately mounted to the body, then each component can be independently installed and maintained, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The mounting carrier integrates multiple mounting functions into a single component structure that simultaneously secures both the battery system and chassis auxiliary frame to the vehicle body, reducing the number of separate mounting operations and fasteners required
Solution Approach 2:
The mounting carrier is designed with pre-configured mounting interfaces and attachment points that enable the battery system and chassis auxiliary frame to be pre-assembled together before final installation to the vehicle body, streamlining the overall assembly process
2Strength
If additional mounting components are added to connect the chassis auxiliary frame and battery system, then load transfer in crash events is improved, but the overall weight of the vehicle substructure increases
Solution Approach 1:
The mounting carrier serves multiple functions simultaneously: it acts as a structural support element, a load transfer path in crash events, and a mounting interface for both the battery system and chassis auxiliary frame, eliminating the need for separate dedicated load transfer components
Solution Approach 2:
The mounting carrier is constructed from composite materials or optimized material combinations that provide high strength and load transfer capability while minimizing weight, achieving superior strength-to-weight ratio compared to traditional single-material mounting solutions
3Area of stationary object
If the battery system is positioned forward of the chassis auxiliary frame, then space for rear axle steering is improved, but the load transfer path in rear impact events becomes longer
Solution Approach 1:
The mounting carrier acts as an intermediary structural element that bridges the spatial gap between the forward-positioned battery system and the chassis auxiliary frame, providing a direct load transfer path that compensates for the increased distance in rear impact events
Data Source
AI summary
A vehicle substructure for a motor vehicle driven at least semi-electrically including at least one chassis auxiliary frame for a rear axle chassis and a battery system arranged in a forward travel direction in front of the chassis auxiliary frame with a battery support structure for receiving at least one battery device. The battery support structure is connected to the body. A mounting carrier serves to transfer a load from the chassis auxiliary frame into the battery support structure in a crash event. The mounting carrier is suitable and configured so as to fixedly connect the chassis auxiliary frame and the battery system to one another prior to being installed in the vehicle, thereby providing a pre-mounting assembly. The mounting carrier can be downwardly disengaged from the chassis auxiliary frame and the battery system after the marriage has been established.