Crash Performance Improvement: The Impact of Engine Mount Crash Plates on Achieving a 5-Star Safety Rating

<div class="section abstract"><div class="htmlview paragraph">Electric vehicles (EVs) differ from internal combustion engine (ICE) vehicles in that they lack a conventional engine and feature an electric drive unit, leading to distinct dynamic behaviours in the powertrain. Additionally, the arrangement of auxiliary components in EVs often differs from that in traditional ICE vehicles, which can sometimes significantly impact safety ratings. This paper examines a case study of a critical failure during a crash test, where displacement of an engine mount arm caused substantial structural intrusion and reduced the vehicle’s safety rating. To address this issue and enhance crashworthiness, a “crash plate” was designed and integrated into the mount system. This solution effectively constrained the mount arm’s movement during impact, preventing the intrusion observed in previous tests. The paper provides a detailed analysis of the crash plate’s dimensions and its relationship to the engine mount, demonstrating its potential for broader application in passenger EVs. This innovative and cost-effective approach significantly improved the vehicle’s crash performance, resulting in a higher safety rating and presenting a new method for enhancing vehicle safety through targeted design improvements.</div></div>