Replacement Floor Assembly for Hybrid Mobility Conversion
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Solution Overview
Problem
Converting OEM hybrid vehicles into mobility assist vehicles is challenging due to the complexity of integrating electric motor and battery systems, which requires careful balancing of design factors and increases conversion time and cost, while maintaining vehicle performance and safety standards.
Innovation Solution
A method involving the removal of the hybrid battery and a portion of the vehicle floor to install a replacement floor assembly that defines a battery well and mobility access system mounting area, allowing the hybrid battery to be reconnected using existing components and enabling the integration of a mobility access system without modifying the suspension or drive system, thus retaining the vehicle's original performance and configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the hybrid battery and floor are removed to install a mobility access system, then wheelchair accessibility is enabled, but interior space and floor integrity are compromised
Solution Approach 1:
The mobility access system is nested within the battery well space that was originally designed to house the hybrid battery. The battery well serves as a cavity that accommodates the mobility access system components, allowing the ramp mechanism to be integrated into the existing floor structure without compromising interior space. The cover plate then restores the floor surface, creating a nested arrangement where the access system is contained within the original battery compartment boundaries.
Solution Approach 2:
The mobility access system utilizes the vertical dimension by deploying the ramp downward into the battery well cavity when needed, rather than requiring horizontal floor space. The ramp folds or telescopes vertically into the battery well compartment, allowing the floor to remain intact during normal use while providing access capability when deployed. This dimensional transition enables accessibility without permanently sacrificing floor area.
2Adaptability or versatility
If the hybrid battery is removed and reinstalled in a new location, then mobility access is achieved, but conversion time and cost increase
Solution Approach 1:
The replacement floor assembly is pre-configured with the battery well and mobility access system mounting areas during manufacturing, before installation in the vehicle. The battery well is pre-formed with appropriate contours and mounting points, eliminating the need for custom fabrication or complex modifications during the conversion process. This preliminary preparation of the floor assembly significantly reduces on-site conversion time and complexity.
Solution Approach 2:
The replacement floor assembly serves multiple functions simultaneously: it provides structural floor support, creates the battery well for hybrid battery installation, and incorporates mounting areas for the mobility access system. This multi-functional design allows a single component to address multiple conversion requirements, reducing the number of separate installation steps and overall conversion time compared to creating each element separately.
3Adaptability or versatility
If the hybrid battery is relocated to a new position, then mobility access system installation is enabled, but battery connection complexity increases
Solution Approach 1:
The replacement floor assembly incorporates universal mounting features and connection points that accommodate both the hybrid battery and mobility access system using standard interfaces. The battery well is designed with mounting structures that align with existing battery connection systems, allowing the battery to be reinstalled in its original configuration without requiring custom wiring or connection adapters. This universal design approach maintains connection simplicity while enabling mobility access integration.
Data Source
AI summary
A replacement floor assembly may include a base member having a top side, a bottom side, a front end, a rear end, a left side, and a right side. The front end and forward portions of the left and right sides define a forward section of the base member, whereas the rear end and rear portions of the left and right sides define a rear section of the base member. A first outboard flange member is mounted to at least a portion of the left side of the base member and a second outboard flange member is mounted to at least a portion of the right side of said base member. A front flange member is mounted to at least a portion of the front end of said base member so that at least portions of the forward section of the base member, the first and second outboard flange members, and the front flange member define a battery well.