Electrified Vehicle Suspension Layout for Larger Battery Packs
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Solution Overview
Problem
Conventional suspension assemblies in vehicles limit the space available for mounting batteries due to their design, which prevents or restricts the size and number of batteries that can be incorporated, especially in electrified vehicles.
Innovation Solution
A suspension assembly design with components primarily located below the frame rail of the chassis, allowing for increased lateral separation between frame rails, thereby providing more space for batteries, and incorporating a lower control arm that integrates steering functions, eliminating the need for a separate steering arm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional suspension assembly design is used, then suspension functionality is maintained, but space for battery mounting is limited
Solution Approach 1:
The suspension assembly components (H-arm, control link, spring) are repositioned from a conventional arrangement to be located primarily below the frame rail, utilizing the vertical dimension more effectively. This dimensional reorganization creates lateral space between frame rails for battery mounting while maintaining all suspension functions.
Solution Approach 2:
The lower control arm is designed with integrated steering functionality, combining what would traditionally be separate components (control arm and steering arm) into a single unified structure. This merging eliminates the need for a separate steering arm, reducing overall assembly complexity and freeing up additional space for battery installation.
2Quantity of substance
If battery size is increased, then electrification capability is enhanced, but suspension assembly space is reduced
Solution Approach 1:
By relocating suspension components below the frame rail, the invention creates lateral space between frame rails that can accommodate larger battery packs. The vertical positioning of suspension elements allows horizontal expansion of battery capacity without compromising suspension functionality.
3Area of stationary object
If lateral separation between frame rails is increased, then battery space is improved, but suspension component arrangement becomes more difficult
Solution Approach 1:
The suspension components are arranged in the vertical dimension below the frame rail, allowing lateral separation between frame rails to be increased for battery space without complicating suspension arrangement. The H-arm and control link are positioned to utilize the space beneath the frame rail, making lateral frame rail separation feasible.
4Ease of operation
If separate steering arm is used, then steering function is achieved, but assembly weight and size increase
Solution Approach 1:
The lower control arm is designed with integrated steering functionality, combining what would traditionally be separate components (control arm and steering arm) into a single unified structure. This merging eliminates the need for a separate steering arm, reducing overall assembly weight and size while maintaining full steering capability through the integrated design.
Solution Approach 2:
The lower control arm serves multiple functions simultaneously: it acts as both the control arm for suspension and the steering arm for steering operations. This multi-functional design eliminates redundant components, reducing assembly weight and complexity while achieving both suspension and steering functions through a single integrated component.
Data Source
AI summary
A suspension assembly for an electrified vehicle includes a knuckle, a subframe, an H-arm coupled between the knuckle and the subframe, a control link arranged above the H-arm and coupled between the knuckle and the subframe, and a spring coupled to a bottom surface of the frame rail. The H-arm and the control link are both arranged below the bottom surface of a frame rail.