Reusable Electric Conversion Kit for H-Frame Chassis
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Solution Overview
Problem
Existing solutions for converting combustion vehicles to electric vehicles do not simplify the process while ensuring compliance with safety regulations and are not reusable, requiring custom configurations for each vehicle.
Innovation Solution
A reusable conversion kit with a frame-mounted electric motor and transmission system that attaches to the existing H-frame chassis without modifying it, using shear bolts to ensure safety compliance during front impacts, and a universal controller to integrate with various vehicle control systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a custom-configured conversion kit is used for each vehicle, then the conversion can be properly adapted to specific vehicle geometries and orientations, but the conversion process becomes time-consuming and complex
Solution Approach 1:
The patent applies universality by designing a standardized conversion kit with a universal mounting frame that can be adapted to different vehicle types (passenger vehicles, light trucks, SUVs) through adjustable mounting brackets and interchangeable connection components. This allows the same basic kit design to serve multiple vehicle configurations without requiring custom fabrication for each vehicle, thereby reducing conversion time while maintaining adaptability.
2Object-generated harmful factors
If the combustion engine is completely replaced with an electric motor system, then the vehicle becomes cleaner and more efficient, but the conversion becomes complex and expensive
Solution Approach 1:
The patent applies segmentation by dividing the powertrain conversion into separate modular components: an electric motor assembly, a battery pack system, a mounting frame structure, and auxiliary systems (cooling, charging). This modular approach allows each component to be independently optimized, installed, and maintained, reducing overall conversion complexity while achieving the environmental benefits of eliminating the combustion engine.
Solution Approach 2:
The patent introduces a universal mounting frame as an intermediary component that mediates between the existing vehicle chassis and the new electric powertrain components. This frame serves as a standardized interface that simplifies integration by providing pre-configured mounting points, alignment features, and connection interfaces, thereby reducing the complexity of directly integrating electric components onto diverse vehicle platforms.
3Ease of operation
If existing vehicle systems are heavily modified to accommodate electric components, then the electric powertrain can be fully integrated, but the conversion cost and complexity increase significantly
Solution Approach 1:
The patent applies the extraction principle by removing the combustion engine and its associated complex systems (intake, exhaust, fuel delivery) and replacing them with a simplified electric motor assembly. The mounting frame is designed to extract only the essential functions needed for powertrain operation while leaving other existing vehicle systems (steering, suspension, braking, electrical systems) largely untouched and compatible with the new powertrain, thereby reducing modification complexity while maintaining ease of operation.
Data Source
AI summary
Suitable for frame vehicles, the kit provides a frame to be mounted on the chassis with attachment devices at a head section and at a middle section of the frame that supports an electric motor, a transmission and at least one battery system. Replacement of the conventional engine and transmission by the frame-mounted unit can be fast. The frame can be attached at the middle section using shear bolts to avoid impeding a crumple of the chassis during a front impact.