Commercial electric vehicle front suspension structure
Described herein are methods and systems of a chassis of a commercial electric vehicle. In various embodiments, the chassis may include a ladder frame with a plurality of frame rails. Batteries and drive units may be packaged within the frame rails of the ladder frame. The chassis may further include an independent front suspension and batteries may be disposed between the suspension members of the independent front suspension.
1 . A commercial electric vehicle comprising:
a ladder frame, comprising a first frame rail and a second frame rail;
a first control arm frame, disposed below the first frame rail and the second frame rail and coupled to the first frame rail and the second frame rail;
a second control arm frame, disposed below the first frame rail and the second frame rail and coupled to the first frame rail and the second frame rail;
a first suspension, comprising:
an first upper control arm assembly, coupled to the first frame rail; and
a first lower control arm assembly, coupled to the first control arm frame, wherein a first portion of the first lower control arm assembly is coupled to the first control arm frame, and wherein a second portion of the first lower control arm assembly is coupled to the second control arm frame;
an electric motor, disposed between the first frame rail and the second frame rail; and
a battery pack, configured to provide electrical power to the electric motor, wherein at least a first portion of the battery pack is disposed between the first frame rail and the second frame rail, and wherein at least a second portion of the battery pack is disposed above the first control arm frame.
2 . The commercial electric vehicle of claim 1 , wherein the second control arm frame is disposed behind the first control arm frame.
3 . The commercial electric vehicle of claim 2 , further comprising:
an anti-roll bar; and
an anti-roll bar bracket, coupled to the anti-roll bar and connected to the first control arm frame to secure the anti-roll bar to the first control arm frame at a substantially fixed distance.
4 . The commercial electric vehicle of claim 1 , wherein the first upper control arm assembly is coupled to the ladder frame at a first point, wherein the first lower control arm assembly is coupled to the first control arm frame at a second point laterally offset from the first point.
5 . The commercial electric vehicle of claim 4 , wherein the second point is inboard of the first point.
6 . The commercial electric vehicle of claim 1 , wherein the first lower control arm assembly comprises:
a bushing; and
a bar pin, disposed within the bushing, wherein the bar pin is coupled to the first control arm frame.
7 . The commercial electric vehicle of claim 1 , wherein the first upper control arm assembly comprises an upper control arm, wherein the first lower control arm assembly comprises a lower control arm, and wherein the lower control arm is longer than the upper control arm.
8 . The commercial electric vehicle of claim 1 , wherein the first suspension further comprises:
an upright, coupled to the first upper control arm assembly and the first lower control arm assembly; and
a wheel, coupled to the upright.
9 . The commercial electric vehicle of claim 1 , wherein the second control arm frame is disposed behind the first control arm frame.
10 . The commercial electric vehicle of claim 1 , wherein the first frame rail comprises a vertical portion, a top horizontal portion coupled to the vertical portion, and a bottom horizontal portion coupled to the vertical portion, and wherein the first control arm frame is coupled to the bottom horizontal portion.
11 . A commercial electric vehicle comprising:
a ladder frame, comprising a first frame rail and a second frame rail;
a first control arm frame, disposed below the first frame rail and the second frame rail and coupled to the first frame rail and the second frame rail;
a first suspension, comprising:
an first upper control arm assembly, coupled to the first frame rail; and
a first lower control arm assembly, coupled to the first control arm frame and comprising:
a bushing; and
a bar pin, disposed within the bushing, wherein the bar pin is coupled to the first control arm frame;
a first fastener, wherein the first fastener couples the bar pin to the first control arm frame and further couples the first control arm frame to the first frame rail
an electric motor, disposed between the first frame rail and the second frame rail; and
a battery pack, configured to provide electrical power to the electric motor, wherein at least a first portion of the battery pack is disposed between the first frame rail and the second frame rail, and wherein at least a second portion of the battery pack is disposed above the first control arm frame.
12 . The commercial electric vehicle of claim 11 , wherein the first control arm frame comprises a first frame attachment point and a second frame attachment point, wherein each of the first frame attachment point and the second frame attachment point are configured to couple to the first lower control arm assembly, and wherein the first lower control arm assembly is coupled to the first frame attachment point.
13 . The commercial electric vehicle of claim 11 , wherein the first frame rail comprises a first rail attachment point and a second rail attachment point, wherein each of the first rail attachment point and the second rail attachment point are configured to couple to the first upper control arm assembly, and wherein the first lower control arm assembly is coupled to the first rail attachment point.
14 . The commercial electric vehicle of claim 11 , wherein the first upper control arm assembly comprises an upper control arm, wherein the first lower control arm assembly comprises a lower control arm, and wherein the lower control arm is longer than the upper control arm.
15 . A commercial electric vehicle comprising:
a ladder frame, comprising a first frame rail and a second frame rail;
a first control arm frame, disposed below the first frame rail and the second frame rail and coupled to the first frame rail and the second frame rail;
a first suspension, comprising:
an first upper control arm assembly, coupled to the first frame rail; and
a first lower control arm assembly, coupled to the first control arm frame;
a second suspension, disposed opposite the first suspension on the commercial electric vehicle and comprising:
a second upper control arm assembly, coupled to the second frame rail; and
a second lower control arm assembly, coupled to the first control arm frame
an electric motor, disposed between the first frame rail and the second frame rail; and
a battery pack, configured to provide electrical power to the electric motor, wherein at least a first portion of the battery pack is disposed between the first frame rail and the second frame rail, and wherein at least a second portion of the battery pack is disposed above the first control arm frame.
16 . The commercial electric vehicle of claim 15 , wherein:
the first suspension further comprises a first damper;
the second suspension further comprises a second damper;
the first frame rail comprises a first shock mount, wherein the first damper is coupled to the first shock mount; and
the second frame rail comprises a second shock mount, and wherein the second damper is coupled to the second shock mount.
17 . The commercial electric vehicle of claim 16 , further comprising:
a shock mount brace, coupled to and spanning across the first shock mount and the second shock mount.
18 . The commercial electric vehicle of claim 17 , wherein the shock mount brace is disposed above the battery pack.
19 . The commercial electric vehicle of claim 15 , further comprising:
a second control arm frame, disposed below the first frame rail and the second frame rail and coupled to the first frame rail and the second frame rail, wherein the first lower control arm assembly and the second control arm assembly are further coupled to the second control arm frame.
20 . The commercial electric vehicle of claim 15 , wherein the first control arm frame is of a forged construction.