Integrated Vehicle Support Beam for Suspension and HV Component Packaging
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Solution Overview
Problem
Existing vehicle designs face challenges in optimizing space utilization, reducing weight and cost, and improving noise, vibration, and harshness characteristics while effectively accommodating and protecting powertrain components like electric drive units.
Innovation Solution
A support beam that integrates structural support and electrical component housing, formed as an integral component with mounting members and a housing portion, providing structural integrity and protection for high voltage electrical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If separate components are used for structural support and electrical component housing, then structural integrity is maintained, but vehicle weight and component count increase
Solution Approach 1:
The patent combines the structural support beam and electrical component housing into a single integrated component. The support beam includes mounting members for suspension components and a housing portion for electrical components, eliminating the need for separate structural and electrical housing parts, thereby reducing vehicle weight while maintaining structural integrity
Solution Approach 2:
The support beam serves multiple functions simultaneously: it provides structural support for the vehicle body, mounting points for suspension components, and housing for high voltage electrical components. This multi-functionality reduces the total number of parts needed while maintaining all necessary structural and electrical functions
2Productivity
If separate components are used for structural support and electrical component housing, then manufacturing simplicity is maintained, but assembly time and manufacturing cost increase
Solution Approach 1:
By integrating the structural beam and electrical housing into one component, the number of assembly operations is reduced. The housing portion is formed as part of the support beam structure, eliminating separate assembly steps for mounting electrical components to a separate housing, thereby reducing assembly time and manufacturing complexity
3Reliability
If more space is allocated for electrical component housing, then electrical component protection is improved, but available vehicle space for other functions is reduced
Solution Approach 1:
The housing portion is integrated into the support beam structure, utilizing the existing structural space efficiently. The housing is positioned between the first and second mounting members, providing protection for electrical components without requiring additional dedicated space, as it shares the volume with the structural support function
Solution Approach 2:
The electrical component housing is nested within the overall support beam structure. The housing portion is contained within the spatial envelope of the support beam, allowing electrical components to be housed within the structural footprint rather than requiring separate external housing space
Data Source
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AI summary
Aspects of the present invention relate to a support beam (100) for a vehicle (400). The support beam (100) is configured to structurally support a first suspension component (302) and a second suspension component (304). The support beam (100) includes a first mounting member (102) configured for connection to the first suspension component (302) at a first side (402) of a vehicle (400); a second mounting member (104) configured for connection to the second suspension component (304) at a second side (404) of a vehicle (400); and a housing portion (106) configured to mount therein high voltage electrical components (206). The housing portion (106) of the support beam (100) is located between the first mounting member (102) of the support beam (100) and the second mounting member (104) of the support beam (100).