Universal Floor Pan Structure for Multi-Drive Vehicle Platforms
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Solution Overview
Problem
Existing motor vehicles with different drive types, such as battery drive, hybrid drive, fuel cell drive, and internal combustion engine drive, have distinct architectures that complicate manufacturing and increase costs due to the need for unique components and assembly processes.
Innovation Solution
The design of a group of motor vehicles with at least two different drive types features a fundamentally identical floor pan assembly structure, including rocker rails, upper and lower floor pans, and a central tunnel structure, which allows for efficient development and construction across different drive concepts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different architectures are used for different drive types, then each vehicle type can be optimized for its specific drive system, but manufacturing complexity increases and costs rise
Solution Approach 1:
The floor pan assembly is designed with a universal structure that can accommodate multiple drive types (internal combustion engine, electric motor, hybrid systems). The same floor pan assembly serves as the mounting base for different energy storage installations (fuel tanks, batteries, capacitors) and drive systems, eliminating the need for drive-type-specific chassis designs and simplifying manufacturing processes
2Adaptability or versatility
If different architectures are used for different drive types, then each vehicle type can have optimized component layout, but manufacturing costs increase
Solution Approach 1:
The floor pan assembly serves multiple functions across different drive types: structural support, mounting platform for energy storage installations, routing channel for lines and hoses, and crash protection structure. This multi-functionality allows a single design to be manufactured for all vehicle types in the group, reducing tooling costs and simplifying production
Solution Approach 2:
The floor pan assembly is divided into functional zones (energy storage installation spaces, routing channels, mounting regions) that can be independently configured for different drive types while maintaining the same overall structure. This segmentation allows optimization for specific drive systems without requiring complete redesign of the entire floor pan assembly
3Reliability
If drive-specific architectures are used, then vehicle performance can be maximized, but production line efficiency decreases
Solution Approach 1:
The floor pan assembly is designed as a universal platform that maintains structural integrity and performance requirements across all drive types. The same assembly line can produce vehicles with different drive systems by simply changing the energy storage installation and associated components, without requiring line reconfiguration, thereby maximizing production efficiency while maintaining vehicle performance
Data Source
AI summary
A group of motor vehicles contains at least vehicles of two different vehicle types of the following vehicle types: a battery drive vehicle with only one electric motor drive, a hybrid drive vehicle with an electric motor drive and an internal combustion engine drive, a fuel cell drive vehicle with a fuel cell drive, and an internal combustion engine drive vehicle with only one internal combustion engine drive. All of the vehicle types of the group of motor vehicles have a base assembly with a left-side sill structure, a right-side sill structure, an upper base, a lower base, and a central tunnel structure.