Steering Column Slot in Structural Battery Pack Layout
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Solution Overview
Problem
Electric vehicles require innovative solutions for integrating battery packs and electric motors with other components like the chassis and suspension system, considering strength, rigidity, and space efficiency, while minimizing weight and size.
Innovation Solution
The battery pack is designed as a structural element that integrates with the chassis, receiving loads from the suspension and steering systems, and includes a battery enclosure made of carbon fiber composite or glass fiber reinforced plastic, which provides structural support and houses battery modules, also accommodating a straight steering column.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the battery pack is designed as a structural element to receive loads from suspension and steering systems, then structural efficiency is improved and additional structural components can be reduced, but the battery enclosure must withstand higher mechanical stresses and loads
Solution Approach 1:
The battery enclosure is designed to perform multiple functions: it houses the battery modules and simultaneously serves as a structural component that receives loads from the suspension system and steering system. This multi-functionality eliminates the need for separate structural components, reducing overall vehicle weight and complexity while improving structural efficiency.
Solution Approach 2:
The battery enclosure is constructed from composite materials that provide both the necessary structural strength to withstand mechanical loads and the protective function for the battery modules. This allows the enclosure to handle higher stresses while maintaining weight efficiency.
2Ease of operation
If the steering column is made straight to improve ride quality, then handling and ergonomics are improved, but the steering column may interfere with the battery pack positioning
Solution Approach 1:
The battery pack is positioned and designed to serve as both the power source and a structural support element for the steering column. The battery enclosure accommodates the steering column mounting, allowing the column to be straight for improved ride quality while the battery pack simultaneously provides structural support and housing functions.
Solution Approach 2:
The steering column is routed through or mounted on the battery pack structure, utilizing the vertical and lateral space around the battery modules. This dimensional arrangement allows the straight steering column to coexist with the battery pack positioning, avoiding interference while maintaining both functions.
3Device complexity
If the battery enclosure serves as a structural element to reduce the number of components, then device complexity is reduced, but the battery pack must be precisely integrated with the chassis and suspension system
Solution Approach 1:
The battery enclosure is merged with the vehicle's structural framework, integrating it with the chassis and suspension system mounting points. This combination reduces the total number of separate structural components while requiring precise integration during manufacturing to ensure proper load transfer and structural alignment.
Data Source
AI summary
An electric vehicle and a powertrain for an electric vehicle are disclosed. According to an embodiment, an electric vehicle includes a steering system with a steering column, and a battery pack having a battery enclosure and a plurality of battery modules housed within the battery enclosure. The battery enclosure defines a slot that extends from at least a top surface of the battery enclosure to receive the steering column.