Scalable Vehicle Frame Platform for ICE and BEV Integration
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Solution Overview
Problem
Existing motor vehicle frames do not efficiently accommodate both internal combustion engines and battery-powered electric vehicles, particularly in terms of scalability, stiffness, and impact protection, while providing adequate cooling and electrical connections.
Innovation Solution
A frame design with cast front and rear transverse sections and extruded longitudinal profiles, incorporating mechanical, electrical, and cooling connector parts, allowing scalability and integration with either engine type, and featuring a central support for varying battery sizes and enhanced crash protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a frame is designed to accommodate both internal combustion engines and battery-powered electric vehicles, then versatility is improved, but device complexity increases
Solution Approach 1:
The frame is designed with universal mounting structures and connector interfaces that can accommodate both internal combustion engines and battery-powered electric motors. The front and rear transverse sections include standardized mechanical connector parts, electrical connector parts, and cooling duct connector parts that serve multiple functions depending on the powertrain type installed.
Solution Approach 2:
The frame is divided into modular sections including front and rear transverse sections with integrated connector parts, and longitudinal side profiles. This segmentation allows independent optimization of each module and facilitates assembly/disassembly for different vehicle configurations.
2Strength
If the frame provides a large degree of stiffness and impact protection, then strength is improved, but weight increases
Solution Approach 1:
The frame utilizes composite construction combining die-cast aluminum transverse sections with extruded aluminum longitudinal profiles. This material selection provides high strength-to-weight ratio, achieving the required stiffness and impact protection while minimizing frame weight.
Solution Approach 2:
The frame incorporates optimized curved geometries in the longitudinal side profiles and transverse sections that enhance structural rigidity and impact resistance. The curved designs provide better load distribution and structural efficiency compared to straight-line constructions.
3Adaptability or versatility
If the frame accommodates battery packs of varying size, then adaptability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The connector parts are designed with localized precision features including form-fitting shapes, ridges, recesses, and alignment bores that ensure accurate positioning. These precision elements are concentrated at the connection interfaces where they are most critical, while other frame portions can be manufactured with standard tolerances.
Solution Approach 2:
The connector parts include pre-formed alignment features such as alignment bores, pins, and form-fitting shapes that guide and constrain components during assembly. This preliminary positioning action ensures accurate alignment before final fastening, reducing the impact of manufacturing tolerances.
4Device complexity
If the frame integrates mechanical, electrical, and cooling connector parts, then device complexity is reduced, but manufacturing complexity increases
Solution Approach 1:
Multiple connector functions are merged into integrated components. The front and rear transverse sections combine mechanical connector parts, electrical connector parts, and cooling duct connector parts into single die-cast aluminum structures, eliminating the need for separate mounting brackets and connection elements.
Solution Approach 2:
The transverse sections serve multiple functions simultaneously: structural support, mechanical connection to subframes, electrical connection for battery and motor, and cooling duct integration. This multi-functionality reduces the total number of components while maintaining manufacturing feasibility through standardized die-casting and extrusion processes.
Data Source
Figure 1
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AI summary
The invention relates to a motor vehicle (1) with a scalable frame (2) that may be used with an internal combustion engine or with an electric drive (51). The vehicle (1) has at least four wheels (6,7,8,9) and a frame (2) with a central support (3) bounded by a front transverse section (20), a rear transverse section (21) and two longitudinal side profiles (23,24). The front and rear transverse sections (20,21) are formed of cast metal with mechanical connector parts (30,31,32,33) attached respectively to a front frame structure (4) and a rear frame structure (5). The front transverse section (20) comprises cooling duct connector parts (40) adapted to be connected to cooling fluid ducts (47,48,49,50) and electrical connector parts (41) adapted to be connected to conductors (52,53,57,58) of an electric motor (51), the rear transverse section (21) comprising electrical connector parts (42) adapted to be connected to an electrical connector (63,64,65,66), such as a charging terminal.