Segmented Lattice Steel Frame for Electric Vehicle Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production processes for electric-propulsion cars with steel frames are time-consuming and costly due to bending and welding techniques, limiting production flexibility and increasing costs, while also compromising on safety and crash performance.
Innovation Solution
The use of a reticular lattice structure with laser-cut, high-tensile steel elements and notches allows for simplified assembly and adaptation of car frames, reducing production time and costs, enhancing flexibility, and improving crash performance by enabling efficient energy absorption in collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional bending and welding techniques are used to assemble steel frame elements, then structural strength and integrity are achieved, but production time and costs increase significantly
Solution Approach 1:
The frame is divided into modular boxed steel elements that can be pre-assembled into complete frame units (main frame and auxiliary frames) separately, then integrated together. This segmentation allows parallel production of different frame components, reducing overall production time while maintaining structural integrity through standardized connection points designed for both welding and mechanical fastening
Solution Approach 2:
The main frame and auxiliary frames are pre-assembled separately before final integration. This preliminary assembly allows each frame type to be manufactured independently using optimized processes, reducing the complexity and time of the final assembly operation while ensuring proper alignment and fit-through pre-drilled holes and standardized connection geometries
2Manufacturing precision
If conventional bending techniques with specially shaped moulds are used, then precise shaping of boxed steel elements is achieved, but production flexibility and equipment costs are reduced
Solution Approach 1:
The design accepts that boxed steel elements will have slight dimensional variations after bending, and compensates for this by incorporating adjustment mechanisms in the connection details. Pre-drilled holes are positioned to accommodate reasonable tolerances, and the connection design allows for minor misalignments without compromising the structural integrity or requiring precision rework
Solution Approach 2:
The connection design serves multiple functions: it provides structural attachment, accommodates dimensional variations from bending processes, and allows for both welding and mechanical fastening methods. This universal connection approach enables the same basic connection detail to work across different production methods and frame configurations, enhancing production flexibility
3Strength
If conventional welding processes are used to integrate frame elements, then strong structural connections are achieved, but production costs and equipment requirements increase
Solution Approach 1:
The connection design incorporates self-aligning features through pre-drilled holes and standardized geometries that guide the assembly process. The holes are positioned and sized to automatically accommodate slight misalignments between mating parts, eliminating the need for complex alignment procedures or specialized tooling while ensuring consistent connection quality across all assembly operations
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 approach results in a more efficient, cost-effective, and flexible production method that enhances safety and crash performance, allowing for easy adaptation of car designs and efficient battery storage, while maintaining structural integrity.
Implementation Method 1
The use of a reticular lattice structure with laser-cut, high-tensile steel elements and notches allows for simplified assembly and adaptation of car frames
Implementation Method 2
enabling efficient energy absorption in collisions
Data Source
AI summary
An electric-propulsion car includes: a main frame, a front axle unit, a rear axle unit, wherein the axle units each have an auxiliary frame for supporting the axle units and two suspension units that connect two respective wheel supports to the supporting auxiliary frame, wherein at least one of the axle units is a motorized axle with steering wheels including, mounted on said auxiliary frame, an electric motor for actuating the rotation of the wheels, a control unit for controlling said electric motor, a transmission unit for connecting the electric motor to the wheels, and a steering device for steering the wheel supports, and wherein each one of the main frame and auxiliary frames includes a reticular lattice structure including boxed elements made of steel, each one of the main frame and auxiliary frames being adapted to be pre-assembled separately and then assembled together. The main frame and auxiliary frames include elements made up of multiple segments connected together and derived from at least one boxed element made of high-tensile steel, wherein the at least one boxed element has at least one notch formed on at least one side of the boxed element without involving an ulterior side of the boxed element, the notch being made on the at least one side at the point where said ulterior side of the boxed element has to be bent to obtain the configuration of the finished boxed element.