Rear Suspension Layout for Wider EV Chassis Battery Packaging
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Solution Overview
Problem
The standard frame width of commercial vehicle chassis limits the variety of battery pack sizes that can be accommodated, particularly in electric vehicles, and restricts the installation of larger devices between the frame rails.
Innovation Solution
A vehicle chassis design with a rear suspension assembly that includes leaf springs mounted below the frame rails and shackles that straddle the frame rails, allowing for a wider frame width without compromising the packaging of rear wheels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the frame width is increased to accommodate larger battery packs and devices, then the adaptability and versatility of the vehicle chassis is improved, but the device complexity and manufacturing difficulty increase due to the need to relocate suspension components
Solution Approach 1:
The suspension assembly is moved from a horizontal arrangement (between frame rails) to a vertical arrangement (below frame rails), utilizing the vertical dimension to resolve the space conflict. This dimensional transition allows the frame width to be increased while maintaining proper suspension function, as the springs and hanger brackets now occupy vertical space rather than horizontal space between the rails.
Solution Approach 2:
The shackle assembly acts as an intermediary component that connects the leaf spring to the frame rail from below, allowing the suspension system to function with the wider frame configuration. The shackle serves as the mediating element that enables the transition from traditional horizontal mounting to the new vertical mounting arrangement.
2Adaptability or versatility
If the frame width is increased, then the adaptability for different battery sizes is improved, but the manufacturing precision requirements worsen due to maintaining constant frame width throughout
Solution Approach 1:
The suspension system is segmented into distinct components (leaf spring, hanger bracket, shackle assembly) that can be independently positioned and adjusted. This segmentation allows the frame to maintain a constant width throughout while the suspension components are configured separately below the rails, reducing the need for complex frame modifications and improving manufacturing consistency.
3Ease of operation
If the rear suspension components are positioned between the frame rails and wheels, then the ease of operation is maintained, but the frame width cannot be increased due to limited space
Solution Approach 1:
The suspension components are relocated from the horizontal dimension (between frame rails) to the vertical dimension (below frame rails). This dimensional change resolves the space conflict by utilizing previously underutilized vertical space, allowing the frame width to be increased while maintaining all suspension functions in their new positioned location.
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 design enables a wider variety of battery sizes to be accommodated, maintains a competitive frame height, and allows for easier manufacturing with a constant frame width, while still accommodating the necessary wheelbase and device installations.
Implementation Method 1
a first leaf spring having a first end and a second end pivotally connected with the first frame rail
Data Source
AI summary
A vehicle chassis with a first frame rail and a second frame rail. There is rear suspension with a first leaf spring and a second leaf spring each pivotally connected to the first and second frame rails, respectively. In some embodiments, the rear suspension includes a first shackle assembly connecting the first leaf spring with the first frame rail such that the first shackle straddles the first leaf spring, and a second shackle assembly similarly straddling the second leaf spring.