Simulation method of commercial vehicle chassis assembly and battery support and vehicle

Abstract

This invention provides a simulation method and vehicle for a commercial vehicle chassis assembly and battery bracket, relating to the field of commercial vehicle chassis design technology. The commercial vehicle chassis assembly includes: two longitudinal beams extending along the length of the vehicle body and positioned opposite each other along the width of the vehicle body; a battery mount assembly comprising a battery mount and a battery bracket, the battery mount being connected to the longitudinal beams and positioned on the outside of the longitudinal beams; one end of the battery bracket being connected to the battery mount, and the other end being connected to the battery system; wherein the battery bracket has multiple connection points for connecting to at least one of a side protection bracket and a work platform bracket. This solution at least solves the problem in the prior art where a direct rigid connection between the battery pack bracket and the vehicle frame is detrimental to battery protection.

Description

Technical Field

[0001] This invention relates to the field of commercial vehicle chassis design technology, and more specifically, to a simulation method for a commercial vehicle chassis assembly and battery bracket, and a vehicle. Background Technology

[0002] The existing battery pack bracket is rigidly connected to the vehicle frame assembly. Excitation from the ground directly affects the battery pack, which is not conducive to battery protection and reduces battery life. The rigid connection of the battery pack results in a large mass, which has a significant impact on the overall vehicle mode and affects comfort.

[0003] There is currently no effective solution to the aforementioned technical problems. Summary of the Invention

[0004] The main objective of this invention is to provide a simulation method and vehicle for a commercial vehicle chassis assembly and battery bracket, in order to solve the problem that the direct rigid connection between the battery pack bracket and the vehicle frame in the prior art is not conducive to battery protection.

[0005] To achieve the above objectives, according to one aspect of the present invention, a commercial vehicle chassis assembly is provided, comprising: two longitudinal beams extending along the length of the vehicle body and arranged opposite to each other along the width of the vehicle body; a battery mount assembly including a battery mount and a battery bracket, the battery mount being connected to the longitudinal beams and disposed on the outside of the longitudinal beams, one end of the battery bracket being connected to the battery mount and the other end of the battery bracket being connected to a battery system; wherein the battery bracket has multiple connection points for connecting to at least one of a side protection bracket and a work platform bracket.

[0006] Furthermore, the battery bracket includes a bracket body and a suspension connecting section. At least a portion of the bracket body extends along the width direction of the vehicle body and is connected to the suspension connecting section. At least a portion of the suspension connecting section extends along the height direction of the vehicle body. The suspension connecting section has at least one bolt connection hole and at least one locating pin hole. The wall thickness of the bolt connection hole gradually decreases from top to bottom along the height direction of the bolt connection section. The bolt connection hole is used to install bolts. The battery bracket and the battery suspension are connected by bolts.

[0007] Furthermore, the battery bracket also includes a battery connection section, which is connected to at least one of the bracket body and the suspension connection section. The battery connection section is provided with a plurality of battery feature connection holes, which are spaced apart along the length direction of the bracket body. The battery feature connection holes are used to connect to the battery system.

[0008] Furthermore, the battery bracket also includes: a protective connecting section, which is connected to at least one of the bracket body and the battery connecting section. At least a portion of the protective connecting section extends along the height direction of the bracket body. The protective connecting section is located on the side of the bracket body away from the battery suspension. The protective connecting section is provided with multiple protective feature connecting holes for connecting with the side protective bracket. A platform connecting section, which is connected to at least one of the bracket body, the protective connecting section, and the suspension connecting section. Along the vehicle height direction, the platform connecting section is located above the battery connecting section. The platform connecting section is provided with multiple platform feature connecting holes for connecting with the work platform bracket. The wall thickness of the battery feature connecting holes is greater than the wall thickness of the protective feature connecting holes, and the wall thickness of the battery feature connecting holes is greater than the wall thickness of the platform feature connecting holes.

[0009] Furthermore, the support body is provided with at least one reinforcing rib and at least one drainage rib. The reinforcing rib is connected to at least one of the suspension connecting section and the battery connecting section, and the drainage rib is connected to at least one of the battery connecting section and the platform connecting section. The battery support is integrally cast.

[0010] Furthermore, the support body is equipped with multiple weight-reduction structures.

[0011] According to another aspect of the present invention, a vehicle is provided having a commercial vehicle chassis assembly, the commercial vehicle chassis assembly being the aforementioned commercial vehicle chassis assembly.

[0012] According to another aspect of the present invention, a simulation method for a battery bracket of a commercial vehicle chassis assembly is also provided. The battery bracket is the aforementioned battery bracket. The method includes: acquiring position information and basic information of the components to be installed, wherein the position information includes at least the installation position of each component to be installed on the chassis assembly, and the basic information includes at least the size and mass of each component to be installed, and the component to be installed includes at least a battery mount and a battery system; determining the location of a characteristic connection point of the battery bracket based on the position information and the basic information, wherein the location of the characteristic connection point is used to determine the connection point between the battery bracket and the component to be installed; generating a simulation model group when the battery bracket is connected to the component to be installed based on the location of the characteristic connection point and the basic information of the component to be installed; and determining the battery bracket structure based on the simulation model group, provided that the strength and weight of the simulation model group meet preset conditions.

[0013] Optionally, based on location information and basic information, the location of the characteristic connection point of the battery bracket is determined. Based on the location of the characteristic connection point and the basic information of the component to be installed, a simulation model group is generated when the battery bracket is connected to the component to be installed. This includes: determining the location of the suspension characteristic connection point of the battery bracket based on the location information of the battery suspension in the component to be installed; and generating a suspension connection segment model in the simulation model group based on the location of the suspension characteristic connection point and the size of the battery suspension in the basic information. The suspension connection segment model is used to simulate the structure of the battery bracket at the battery suspension.

[0014] Optionally, based on location information and basic information, the location of the characteristic connection point of the battery bracket is determined. Based on the location of the characteristic connection point and the basic information of the component to be installed, a simulation model group is generated when the battery bracket is connected to the component to be installed. This includes: determining the location of the battery characteristic connection point of the battery system based on the location information of the battery system in the component to be installed; and generating a battery connection segment model in the simulation model group based on the location of the battery characteristic connection point and the size and mass of the battery system in the basic information. The battery connection segment model is used to simulate the structure of the battery bracket at the battery system.

[0015] By applying the technical solution of this invention, a battery mounting assembly is installed on the chassis assembly. The battery mounting is mounted on the longitudinal beams and connected to and supports the battery system via a battery bracket. This allows the battery pack bracket of the battery system to avoid being directly rigidly connected to the vehicle frame assembly. Instead, the battery bracket and battery mounting are flexibly connected to the longitudinal beams of the vehicle frame, acting as a buffer. This avoids the significant impact of a rigidly connected battery system on the overall vehicle's modal characteristics, thus reducing the impact on vehicle comfort and improving the battery system's lifespan. Furthermore, multiple connection points on the battery bracket can connect to the side protection brackets and the work platform bracket, further enhancing the stability of the battery bracket and battery system. This integrated design of the work platform, side protection plates, and battery system increases the overall connection stability of the three components. Attached Figure Description

[0016] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0017] Figure 1 A schematic diagram of a first embodiment of a commercial vehicle chassis assembly according to the present invention is shown;

[0018] Figure 2 A schematic diagram of a second embodiment of a commercial vehicle chassis assembly according to the present invention is shown;

[0019] Figure 3 A schematic diagram of a first embodiment of the battery suspension assembly according to the present invention is shown;

[0020] Figure 4 A schematic diagram of a second embodiment of the battery suspension assembly according to the present invention is shown;

[0021] Figure 5 A flowchart of a simulation method for a commercial vehicle chassis assembly battery bracket according to the present invention is shown.

[0022] The above figures include the following reference numerals:

[0023] 10. Longitudinal beams;

[0024] 20. Battery suspension assembly; 21. Battery suspension; 22. Battery bracket; 221. Bracket body; 2210. Weight reduction structure; 2211. Reinforcing rib; 2212. Drainage rib; 222. Suspension connection section; 2221. Bolt connection hole; 2222. Locating pin hole; 223. Battery connection section; 2230. Battery feature connection hole; 224. Protective connection section; 2240. Protective feature connection hole; 225. Platform connection section; 2250. Platform feature connection hole;

[0025] 30. Battery system;

[0026] 40. Side protective brackets;

[0027] 50. Work platform support. Detailed Implementation

[0028] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0029] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0030] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such terms can be used interchangeably where appropriate so that the embodiments of this application described herein can be implemented, for example, in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0031] Exemplary embodiments according to this application will now be described in more detail with reference to the accompanying drawings. However, these exemplary embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. It should be understood that these embodiments are provided so that the disclosure of this application is thorough and complete, and that the concept of these exemplary embodiments is fully conveyed to those skilled in the art. In the drawings, for clarity, the thickness of layers and regions may be exaggerated, and the same reference numerals are used to denote the same devices, and therefore their description will be omitted.

[0032] Combination Figures 1 to 4 As shown in the specific embodiment of this application, a commercial vehicle chassis assembly is provided.

[0033] Specifically, such as Figure 1 , Figure 2 As shown, the commercial vehicle chassis assembly includes longitudinal beams 10 and battery mount assembly 20. There are two longitudinal beams 10, which extend along the length of the vehicle body and are arranged opposite each other along the width of the vehicle body. The battery mount assembly 20 includes a battery mount 21 and a battery bracket 22. The battery mount 21 is connected to the longitudinal beams 10 and is located on the outside of the longitudinal beams 10. One end of the battery bracket 22 is connected to the battery mount 21, and the other end of the battery bracket 22 is connected to the battery system 30. The battery bracket 22 has multiple connection points, which are used to connect to at least one of the side protection bracket 40 and the work platform bracket 50.

[0034] By applying the technical solution of this embodiment, a battery mounting assembly 20 is installed on the chassis assembly, and a battery mount 21 is installed on the longitudinal beam 10. The battery system 30 is connected and supported by a battery bracket 22. This allows the battery pack bracket of the battery system 30 to avoid being directly rigidly connected to the vehicle frame assembly. Instead, the battery bracket 22 and battery mount 21 are flexibly connected to the longitudinal beam 10 of the vehicle frame, acting as a buffer. This avoids the significant impact of a rigid connection between the battery system 30 and the overall vehicle mode, thus affecting vehicle comfort and improving the lifespan of the battery system 30. Furthermore, multiple connection points on the battery bracket 22 can be connected to the side protection bracket 40 and the work platform bracket 50, further enhancing the stability of the battery bracket 22 and the battery system 30. This integrated design of the work platform, side protection plate, and battery system 30 increases the overall connection stability of the three components.

[0035] Specifically, such as Figure 3 As shown, the battery bracket 22 includes a bracket body 221 and a suspension connecting section 222. At least a portion of the bracket body 221 extends along the width direction of the vehicle body and is connected to the suspension connecting section 222. At least a portion of the suspension connecting section 222 extends along the height direction of the vehicle body. The suspension connecting section 222 has at least one bolt connection hole 2221 and at least one positioning pin hole 2222. The wall thickness of the bolt connection hole 2221 gradually decreases from top to bottom along the height direction of the suspension connecting section 222. The bolt connection hole 2221 is used to install bolts. The battery bracket 22 and the battery suspension 21 are connected by bolts. The suspension connection section 222 is mainly used to connect with the battery suspension 21. Based on the specific structure of the battery suspension 21, bolt connection holes 2221 and locating pin holes 2222 are provided on the suspension connection section 222. The locating pin holes 2222 are used to engage with locating pins on the battery suspension 21. By extending the locating pins into the locating pin holes 2222, precise positioning can be achieved during the assembly process of the battery system 30, improving overall assembly efficiency. Simultaneously, after the locating pins and locating pin holes 2222 have engaged and positioned, bolts are passed through the bolt connection holes 2221 to securely connect the battery bracket 22 to the battery suspension 21.

[0036] It should be noted that, to improve structural strength and fatigue resistance, the wall thickness of the bolt connection hole 2221 gradually decreases from top to bottom along the height direction of the suspension connection section 222, forming a gradually thickened wall structure. Based on load transfer path analysis, during vehicle operation, the mass inertial force from the battery pack and road excitation mainly act upwards on the bolt connection area through the battery suspension 21. The stress concentration points are mostly located in the upper part of the connection hole. Therefore, by using a hole wall structure that is thicker at the top and thinner at the bottom, the material distribution is made to better match the actual stress distribution. This ensures the structural reliability of the connection area under high load conditions while effectively reducing the overall weight, achieving a synergistic optimization of lightweighting and strength.

[0037] In one embodiment of this application, such as Figure 3 , Figure 4 As shown, the suspension connection section 222 is Y-shaped from top to bottom along the vehicle height direction. Each of the two arms of the Y-shape above the suspension connection section 222 has a bolt connection hole 2221. A positioning pin hole 2222 is provided in the middle of the suspension connection section 222. During the installation of the battery system 30, the battery system 30 is lifted from bottom to top. After the positioning pin hole 2222 is aligned with the positioning pin on the battery suspension 21, the bolt connection holes 2221 at both ends of the Y-shaped suspension connection section 222 are connected to the battery suspension 21 by bolts, thereby fixing the battery bracket 22 to the battery suspension 21.

[0038] Furthermore, such as Figure 3 As shown, the battery bracket 22 also includes a battery connection section 223, which is connected to at least one of the bracket body 221 and the suspension connection section 222. The battery connection section 223 is provided with a plurality of battery feature connection holes 2230, which are spaced apart along the length of the bracket body 221. The battery feature connection holes 2230 are used to connect to the battery system 30. The battery connection section 223 is connected to the middle of the bracket body 221 and to the end of the suspension connection section 222. Based on the dimensions of the battery system 30, the battery connection section 223 is extended along the width of the vehicle body. This allows the main load-bearing portion of the battery connection section 223 to extend along the distribution of the battery system 30, evenly bearing the weight of the battery system 30 on the battery bracket 22, thereby enhancing the overall rigidity of the battery bracket 22. In addition, the battery connection section 223 is provided with a plurality of battery feature connection holes 2230. The battery feature connection holes 2230 are arranged at intervals along the length direction of the bracket body 221 (i.e., the longitudinal direction of the vehicle), and their positions correspond one-to-one with the preset mounting points on the bottom or side of the battery system 30, which facilitates the installation and removal of the battery system 30.

[0039] In this embodiment, the battery feature connection hole 2230 is a through hole or countersunk hole structure, adapted to the corresponding bolts, quick-release clips or positioning pins on the battery system 30, to achieve rigid positioning and reliable fixation between the battery system 30 and the battery bracket 22. At the same time, the multi-point spaced arrangement of the battery feature connection hole 2230 can effectively disperse the local load of the battery system 30, avoid stress distortion caused by concentrated connection, and improve the structural stability of the battery system 30 under vibration and impact conditions.

[0040] It should be noted that the battery bracket 22 achieves the "three-point constraint + elastic vibration isolation" connection mode of the battery system 30 through the lateral bearing of the bracket body 221, the multi-point longitudinal distribution connection of the battery connection section 223, and the vertical elastic suspension of the suspension connection section 222. This can effectively isolate the transmission of road excitation to the battery system 30, while reducing the negative impact of the battery system as a large mass rigid body on the overall vehicle mode.

[0041] Furthermore, the battery bracket 22 also includes a protective connecting section 224 and a platform connecting section 225. The protective connecting section 224 is connected to at least one of the bracket body 221 and the battery connecting section 223. At least a portion of the protective connecting section 224 extends along the height direction of the bracket body 221. The protective connecting section 224 is located on the side of the bracket body 221 away from the battery suspension 21. The protective connecting section 224 is provided with a plurality of protective feature connecting holes 2240 for connecting with the side protective bracket 40. The platform connecting section 225 is connected to the bracket body 221. At least one of the following connections—body 221, protective connecting section 224, and suspension connecting section 222—is connected along the vehicle height direction. Platform connecting section 225 is positioned above battery connecting section 223. Platform connecting section 225 has multiple platform feature connecting holes 2250 for connecting to the work platform bracket 50. The wall thickness of the battery feature connecting hole 2230 is greater than that of the protective feature connecting hole 2240, and the wall thickness of the battery feature connecting hole 2230 is greater than that of the platform feature connecting hole 2250. Protective connecting section 224 is located on the side of the bracket body 221 away from the battery suspension 21 (i.e., the outer side of the vehicle frame) and is used to install a side protective bracket 40. The side protective bracket 40 is used to install a side protective plate, which mainly provides collision protection and auxiliary support. Platform connecting section 225 is positioned above battery connecting section 223 and bracket body 221 and is used to connect a platform bracket. The platform bracket is used to connect a work platform, which mainly bears static loads and worker loads. Meanwhile, the load matching of functional zones is achieved through the wall thickness design of each feature connection hole. The load level of the side protection plate is much lower than that of the battery connection point. Therefore, the wall thickness of the protection feature connection hole 2240 is smaller than that of the battery feature connection hole 2230, realizing differentiated design, material saving and lightweight optimization. Moreover, the load level of the working platform is the lowest, and the wall thickness of the platform feature connection hole 2250 is also smaller than that of the battery feature connection hole 2230, and preferably smaller than that of the protection feature connection hole 2240, so as to further optimize the material distribution and reduce the overall weight.

[0042] Furthermore, the support body 221 is provided with at least one reinforcing rib 2211 and at least one flow guide rib 2212. The reinforcing rib 2211 is connected to at least one of the suspension connecting section 222 and the battery connecting section 223, and the flow guide rib 2212 is connected to at least one of the battery connecting section 223 and the platform connecting section 225. The battery support 22 is integrally cast. Since the battery support 22 is integrally cast, after determining the structure and size of the battery support 22, flow guide ribs 2212 need to be set at specific positions to meet the casting process requirements. The flow guide ribs 2212 can effectively guide the flow of molten metal in the mold. By setting the flow guide ribs 2212 to be connected to the battery connecting section 223 and the platform connecting section 225, the flow of molten metal between the battery connecting section 223 and the platform connecting section 225 can be guided, ensuring that the molten metal is distributed on the support body 221 according to the preset structure. It also promotes the discharge of air bubbles during the casting process and improves the overall quality and structural stability of the casting. A reinforcing rib 2211 is provided between the suspension connection section 222 and the battery connection section 223. Since the suspension connection section 222 is mainly responsible for connecting with the battery suspension 21 and the battery connection section 223 is mainly responsible for connecting with the battery system 30, both of them are high-load areas and need to withstand large stresses. Therefore, the additional reinforcing rib 2211 between them can increase the bending stiffness and local deformation resistance of the suspension connection section 222 and the battery connection section 223, and can effectively suppress the vibration response of the battery system 30 under rapid acceleration, sudden braking or bumpy conditions.

[0043] In one exemplary embodiment of this application, the battery bracket 22 is manufactured in one piece using a thick plate stamping process, which avoids stress concentration and fatigue risks caused by welding and improves the overall rigidity and durability of the structure.

[0044] Furthermore, multiple weight-reduction structures 2210 are provided on the bracket body 221. By optimizing the structure of the non-load-bearing area of ​​the bracket body 221 and removing redundant materials without affecting the connection strength and overall rigidity of the bracket body 221 and the suspension connection section 222, the overall weight of the battery bracket 22 is significantly reduced while maintaining its function as a connection point with components such as the battery suspension 21, side protection bracket 40, and work platform bracket 50. The distribution of the weight-reduction structures 2210 takes into account both the continuity of the mechanical force transmission path and the feasibility of the manufacturing process, effectively reducing the self-weight of the battery bracket 22, thereby reducing the unsprung mass of the vehicle, improving the dynamic response speed and energy utilization efficiency of the chassis system, and achieving the goal of lightweighting without increasing manufacturing costs.

[0045] According to another specific embodiment of this application, a vehicle is also provided, which has a commercial vehicle chassis assembly, the commercial vehicle chassis assembly of the above embodiment. Applying the commercial vehicle chassis assembly of the above embodiment to a vehicle effectively integrates the installation functions of peripheral chassis components while achieving vibration isolation of the battery mount 21, reducing the number of independent brackets, lowering the overall vehicle weight, improving assembly efficiency, and isolating vibration excitation from the road surface through the battery mount assembly 20, reducing the transmitted noise between the battery system 30 and the chassis, and improving the overall vehicle ride comfort.

[0046] like Figure 5 As shown, according to another specific embodiment of this application, a simulation method for a commercial vehicle chassis assembly battery bracket is also provided, wherein the battery bracket is the battery bracket in the above embodiment, and the method includes:

[0047] Step S10: Obtain the location information and basic information of the components to be installed. The location information includes at least the installation position of each component to be installed on the chassis assembly, and the basic information includes at least the size and weight of each component to be installed. The components to be installed include at least the battery mount and the battery system.

[0048] Specifically, the installation position of each component to be installed on the chassis assembly includes the three-dimensional spatial coordinates of each component to be installed in the chassis coordinate system, the relative positional relationship of each component's installation point to the frame longitudinal beam, and the installation position such as spatial distribution density and geometric layout.

[0049] Step S20: Based on location information and basic information, determine the location of the characteristic connection point of the battery bracket, wherein the location of the characteristic connection point is used to determine the connection point between the battery bracket and the component to be installed;

[0050] Specifically, after obtaining the location and basic information of the components to be installed, the system calculates and determines the precise three-dimensional spatial position of each feature connection point on the battery bracket through spatial geometric mapping and mechanical load coupling analysis. The position of the feature connection point is used to define the physical connection boundary between the battery bracket and each component to be installed.

[0051] In step S20, the preset installation point coordinates of the component to be installed in the chassis coordinate system are used as the target point. The target point is mapped to the theoretical design space of the battery bracket through rigid body transformation (translation + rotation) to ensure that the corresponding battery feature connection point on the bracket coincides with the mounting hole position of the battery system.

[0052] Step S30: Based on the location of the feature connection points and the basic information of the component to be installed, generate a set of simulation models when the battery bracket is connected to the component to be installed.

[0053] Specifically, a finite element model of the battery bracket is constructed, and the models of each part of the battery bracket constitute the model combination of the battery bracket.

[0054] Step S40: After determining that the strength and weight of the simulation model group meet the preset conditions, determine the battery bracket structure based on the simulation model group.

[0055] Specifically, static and transient dynamic analyses are performed on the simulation model group to obtain the maximum equivalent stress distribution of the support under all preset working conditions. When the strength of the battery support meets the preset conditions, the system determines that the support topology corresponding to the current simulation model group is the final output structure.

[0056] It should be noted that the preset conditions are data thresholds pre-set in the system based on the structure and location of the chassis assembly. When the strength data, mass data and other parameters of the simulation model group meet the thresholds in the preset conditions, it can be determined that the simulation model of the battery bracket meets the structural strength requirements, and thus the structure of the battery bracket can be determined.

[0057] Through the above steps, the location information and basic information of the components to be installed are obtained. The location information includes at least the installation position of each component on the chassis assembly, and the basic information includes at least the size and weight of each component. The components to be installed include at least the battery mount and the battery system. Based on the location information and basic information, the location of the characteristic connection points of the battery bracket is determined. The location of the characteristic connection points is used to determine the connection points between the battery bracket and the components to be installed. Based on the location of the characteristic connection points and the basic information of the components to be installed, a simulation model group is generated when the battery bracket is connected to the components to be installed. If the strength and weight of the simulation model group meet the preset conditions, the structure of the battery bracket is determined based on the simulation model group. By acquiring the installation position, dimensions, and mass information of the battery mount and battery system on the chassis, a simulation model group is constructed based on the characteristic connection point positions between the battery bracket and the battery mount and battery system. Combined with the layout characteristics of the connection points on the battery bracket, the collaborative stress state of the battery bracket and multiple components such as longitudinal beams, side protection, and work platform brackets is simulated. Under the constraints of strength and weight, the bracket structure is optimized, effectively improving the consistency between the simulation results and the actual vehicle assembly conditions. This provides data support for the structural design of the battery mount and battery connection bracket, shortens the development cycle, and reduces the cost of prototype manufacturing.

[0058] Optionally, in steps S20-S30, based on location information and basic information, the location of the characteristic connection point of the battery bracket is determined; based on the location of the characteristic connection point and the basic information of the component to be installed, a simulation model group is generated when the battery bracket is connected to the component to be installed, including:

[0059] Step S21: Based on the position information of the battery suspension in the component to be installed, determine the position of the suspension feature connection point of the battery bracket;

[0060] Specifically, the battery mounting boundary data is obtained, and the battery mounting connection point is aligned with the chassis coordinate system through rigid body transformation to determine the spatial coordinates of the battery bracket and the battery mounting connection point in the chassis system.

[0061] Step S22: Based on the location of the suspension feature connection point and the size of the battery suspension in the basic information, generate the suspension connection segment model in the simulation model group. The suspension connection segment model is used to simulate the structure of the battery bracket at the battery suspension.

[0062] Specifically, the actual geometric dimensions (such as flange profile and bolt hole distribution), assembly parameters (such as clearance and preload), and dynamic characteristics (such as stiffness curve) of the battery suspension are input into the simulation system to reconstruct the connection area between the battery bracket and the suspension using a realistic 3D model, thus constructing a suspension connection segment model.

[0063] By using steps S21-S22, the location of the suspension feature connection point and the geometric dimensions of the battery suspension are used as modeling inputs, enabling the simulation model to accurately reflect the stiffness distribution, load transfer path, and deformation response of the connection area. This overcomes the accuracy loss problem caused by simplifying the connection part to a rigid node or a general connection unit in traditional simulations, and significantly improves the accuracy of predicting the structural performance of the battery bracket under vibration and impact conditions.

[0064] Optionally, in steps S20-S30, based on location information and basic information, the location of the characteristic connection point of the battery bracket is determined; based on the location of the characteristic connection point and the basic information of the component to be installed, a simulation model group is generated when the battery bracket is connected to the component to be installed, including:

[0065] Step S23: Based on the location information of the battery system in the component to be installed, determine the location of the battery feature connection point of the battery system;

[0066] Specifically, the installation boundary data of the battery pack, battery casing, battery tray and other structures in the battery system are obtained, and the connection points of the battery system are aligned with the chassis coordinate system through rigid body transformation to determine the spatial coordinates of the connection points of the battery bracket and the battery system in the chassis system.

[0067] Step S24: Based on the location of the battery feature connection point and the size and mass of the battery system in the basic information, generate the battery connection segment model in the simulation model group. The battery connection segment model is used to simulate the structure of the battery bracket at the battery system.

[0068] Specifically, based on the actual three-dimensional dimensions, overall mass (including the centroid of distribution), and coordinates of bottom and lateral feature connection points of the battery system (cell modules, housing, BMS, cooling pipes, etc.), a battery connection segment model is generated in the simulation model group. This model is a high-fidelity subsystem of a rigid mass block coupled with multi-point constraints, used to accurately simulate the load transfer boundary conditions between the battery pack and the battery bracket.

[0069] Through steps S23-S24, by accurately obtaining the three-dimensional dimensions, total mass distribution, and centroid position of the battery system, and combining them with the coordinates of the characteristic connection points between the battery system and the battery support, a "battery connection segment model" with rigid body-multi-point constraint coupling is constructed in the simulation model group. This restores the way in which the battery pack, as a large-mass rigid excitation source, applies loads to the support, replacing the traditional rough modeling that is simplified to a concentrated mass or homogeneous shell.

[0070] In one exemplary embodiment of this application, after generating the battery connection segment model and the suspension connection segment model in the simulation model group, based on the connection point positions of the working platform and the working platform support, and the connection point positions of the side protection plate and the side protection connection support, and basic information, the side protection connection segment model and the working platform connection segment model can also be generated. The connection segment models are combined to form the simulation model group, and if the strength data, stiffness data, and mass data parameters of each connection segment model meet the preset thresholds in the system, the simulated battery support structure can be finally determined based on the simulation model group.

[0071] This application also provides a preferred embodiment of a commercial vehicle chassis assembly. Compared with the transmission battery frame, by adding the battery suspension assembly 20, the transmission of vibration is effectively isolated, protecting the battery pack while isolating the large mass rigid body of the battery pack from the excitation of the commercial vehicle chassis. This is beneficial to improving the comfort of electric commercial vehicles, reducing vibration and noise, and enhancing the user experience.

[0072] Specifically, the commercial vehicle chassis assembly includes a battery system 30, battery mounts 21, battery brackets 22, and longitudinal beams 10. The battery system 30 is connected to the longitudinal beams 10 via six sets of battery mounts 21. One end of the battery bracket 22 is connected to the support plate of the battery system 30, and the other end is connected to the battery mounts 21. The battery bracket 22 is manufactured using a thick plate stamping process. During assembly, the battery system 30 is first assembled separately, with the battery system 30 and battery brackets 22 assembled into a single unit, and the battery mounts 21 are separately assembled onto the longitudinal beams 10. The battery system 30 and battery brackets 22 are lifted from bottom to top, and after being lifted to the designated position, the battery mounts 21 and battery brackets 22 are connected by bolts through the engagement of the locating pins on the battery mounts 21 and the locating pin holes 2222 on the battery brackets 22.

[0073] The battery bracket 22 is a combined bracket that integrates multiple functions to achieve the goal of integrated and lightweight design. The battery feature connection hole 2230 is used to connect and fix it to the tray of the battery system 30. The protection feature connection hole 2240 is used to connect to the side protection bracket 40. The platform feature connection hole 2250 is used to connect to the work platform bracket 50. The bolt connection hole 2221 is used to connect to the battery suspension 21.

[0074] As can be seen from the above description, the commercial vehicle chassis assembly in the above embodiments has the following beneficial effects:

[0075] The commercial vehicle chassis assembly uses two longitudinal beams 10 extending along the length of the vehicle body and arranged opposite each other along the width of the vehicle body as the main load-bearing structure. A battery mount 21 is set on the outside of the longitudinal beams 10. The mount realizes a non-rigid connection between the battery system 30 and the longitudinal beams 10, thereby introducing an elastic buffer in the vibration transmission path and effectively isolating the direct transmission of high-frequency vibration and impact from the chassis longitudinal beams 10 to the battery system 30. At the same time, one end of the battery bracket 22 is connected to the battery mount 21 and the other end is fixed to the battery system 30, forming a stable and flexible force transmission channel. Multiple connection base points set on it can be directly connected to at least one of the side protection brackets 40 or the work platform brackets 50 to realize the integrated installation of auxiliary components. This design eliminates the problem of vibration transmission without attenuation caused by the traditional solution where the battery pack is directly fixed to the longitudinal beam 10 or sub-beam through multiple rigid points. It avoids structural resonance and noise amplification caused by multi-point rigid constraints. Without adding additional connecting parts, the multi-functional integrated design of the battery bracket 22 maintains the integrity and lightweight of the vehicle structure, while ensuring the stable suspension and vibration isolation of the battery system 30 under complex working conditions. This systematically solves the technical problem of high vibration and noise and low reliability caused by rigid connection of the battery pack, and significantly improves the durability of the battery system 30 and the overall vehicle ride comfort.

[0076] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0077] In addition to the above, it should be noted that the terms "one embodiment," "another embodiment," and "embodiment" used in this specification refer to specific features, structures, or characteristics described in connection with that embodiment, which are included in at least one embodiment described in the general description of this application. The appearance of the same expression in multiple places in the specification does not necessarily refer to the same embodiment. Furthermore, when a specific feature, structure, or characteristic is described in connection with any embodiment, the intention is to suggest that implementing such a feature, structure, or characteristic in conjunction with other embodiments also falls within the scope of this invention.

[0078] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0079] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A commercial vehicle chassis assembly, characterized in that, include: There are two longitudinal beams (10), which extend along the length of the vehicle body and are arranged opposite each other along the width of the vehicle body. A battery suspension assembly (20) includes a battery suspension (21) and a battery bracket (22). The battery suspension (21) is connected to the longitudinal beam (10) and is located on the outside of the longitudinal beam (10). One end of the battery bracket (22) is connected to the battery suspension (21), and the other end of the battery bracket (22) is connected to the battery system (30). The battery bracket (22) has multiple connection points, which are used to connect to at least one of the side protection bracket (40) and the work platform bracket (50).

2. The commercial vehicle chassis assembly according to claim 1, characterized in that, The battery bracket (22) includes a bracket body (221) and a suspension connecting section (222). At least a portion of the bracket body (221) extends along the width direction of the vehicle body and is connected to the suspension connecting section (222). At least a portion of the suspension connecting section (222) extends along the height direction of the vehicle body. The suspension connecting section (222) has at least one bolt connection hole (2221) and at least one positioning pin hole (2222). The wall thickness of the bolt connection hole (2221) gradually decreases from top to bottom along the height direction of the suspension connecting section (222). The bolt connection hole (2221) is used to install bolts. The battery bracket (22) and the battery suspension (21) are connected by the bolts.

3. The commercial vehicle chassis assembly according to claim 2, characterized in that, The battery bracket (22) further includes a battery connection section (223), which is connected to at least one of the bracket body (221) and the suspension connection section (222). The battery connection section (223) is provided with a plurality of battery feature connection holes (2230), which are spaced apart along the length direction of the bracket body (221). The battery feature connection holes (2230) are used to connect to the battery system (30).

4. The commercial vehicle chassis assembly according to claim 3, characterized in that, The battery holder (22) also includes: A protective connecting section (224) is connected to at least one of the bracket body (221) and the battery connecting section (223). At least a portion of the protective connecting section (224) extends along the height direction of the bracket body (221). The protective connecting section (224) is located on the side of the bracket body (221) away from the battery suspension (21). The protective connecting section (224) is provided with a plurality of protective feature connecting holes (2240), which are used to connect with the side protective bracket (40). Platform connecting section (225), which is connected to at least one of the bracket body (221), the protective connecting section (224), and the suspension connecting section (222). Along the vehicle height direction, the platform connecting section (225) is located above the battery connecting section (223). The platform connecting section (225) is provided with a plurality of platform feature connecting holes (2250), which are used to connect with the working platform bracket (50). The wall thickness of the battery feature connection hole (2230) is greater than that of the protective feature connection hole (2240), and the wall thickness of the battery feature connection hole (2230) is greater than that of the platform feature connection hole (2250).

5. The commercial vehicle chassis assembly according to claim 4, characterized in that, The bracket body (221) is provided with at least one reinforcing rib (2211) and at least one drainage rib (2212). The reinforcing rib (2211) is connected to at least one of the suspension connecting section (222) and the battery connecting section (223). The drainage rib (2212) is connected to at least one of the battery connecting section (223) and the platform connecting section (225). The battery bracket (22) is integrally cast.

6. The commercial vehicle chassis assembly according to any one of claims 2-5, characterized in that, The support body (221) is provided with multiple weight reduction structures (2210).

7. A vehicle, characterized in that, The vehicle has a commercial vehicle chassis assembly, which is the commercial vehicle chassis assembly according to any one of claims 1-6.

8. A simulation method for a commercial vehicle chassis assembly battery bracket, characterized in that, The battery holder is the battery holder according to any one of claims 1-6, and the method includes: Obtain the location information and basic information of the components to be installed, wherein the location information includes at least the installation position of each component to be installed on the chassis assembly, and the basic information includes at least the size and mass of each component to be installed, and the component to be installed includes at least a battery mount and a battery system; Based on the location information and the basic information, the location of the characteristic connection point of the battery bracket is determined, wherein the location of the characteristic connection point is used to determine the connection point between the battery bracket and the component to be installed; Based on the location of the feature connection point and the basic information of the component to be installed, a set of simulation models is generated when the battery bracket is connected to the component to be installed. If the strength and weight of the simulation model group meet the preset conditions, the battery bracket structure is determined based on the simulation model group.

9. The method according to claim 8, characterized in that, Based on the location information and the basic information, the location of the characteristic connection point of the battery bracket is determined. Based on the location of the characteristic connection point and the basic information of the component to be installed, a simulation model set is generated when the battery bracket is connected to the component to be installed, including: Based on the position information of the battery suspension in the component to be installed, the position of the suspension feature connection point of the battery bracket is determined; Based on the location of the suspension feature connection point and the dimensions of the battery suspension in the basic information, a suspension connection segment model is generated in the simulation model group, wherein the suspension connection segment model is used to simulate the structure of the battery bracket at the battery suspension.

10. The method according to claim 9, characterized in that, Based on the location information and the basic information, the location of the characteristic connection point of the battery bracket is determined. Based on the location of the characteristic connection point and the basic information of the component to be installed, a simulation model set is generated when the battery bracket is connected to the component to be installed, including: Based on the location information of the battery system in the component to be installed, the location of the battery feature connection point of the battery system is determined; Based on the location of the battery feature connection point and the size and mass of the battery system in the basic information, a battery connection segment model is generated in the simulation model group, wherein the battery connection segment model is used to simulate the structure of the battery bracket at the battery system.

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