Mounting system for accessory units on vehicles

Abstract

The present invention relates to a system for mounting an accessory unit to a vehicle. The mounting system comprises at least one side channel, the at least one side channel being attached to the accessory unit, and at least one screw strip, the at least one screw strip comprising a plate having a plurality of screws, the plurality of screws being assembled at predetermined positions defined by matching mounting positions of at least one bushing. The screw strip is movably mounted in the side channel. The system further comprises at least one bracket, the at least one bracket being arranged to receive screws assembled on the screw strip and to receive a nut for each screw, the nut being arranged to secure the mounting system by pressing the screw towards a locking device in the side channel, and wherein the bracket is arranged to receive a frame mounted bushing, the frame mounted bushing being mounted to a side rail of a vehicle frame.

Description

Technical Field

[0001] The present invention relates to a mounting device for an accessory unit on a vehicle, and in particular to a flexible and expandable stepless interface.

[0002] The invention may be applied to heavy vehicles such as trucks, buses and construction equipment.Although the invention will be described with respect to a lorry, the invention is not limited to this particular vehicle but may also be used in other vehicles such as heavy construction equipment. Background Art

[0003] Recent developments in the automotive sector have been focused on electric drive solutions; this also applies to heavy-duty vehicles such as trucks, buses, and construction equipment. This has driven the need for new solutions around the drivetrain, energy storage, construction, and assembly of these types of vehicles. Generally speaking, heavy-duty vehicles are often specially designed for specific situations or have a number of different accessory units installed on the vehicle depending on the function and vehicle type. For example, energy storage systems such as batteries are generally heavy and occupy a large volume in automotive applications. This is especially true for heavy-duty vehicles that operate for long periods of time every day and carry heavy loads. Furthermore, because these types of vehicles involve small manufacturing series, often specially designed solutions, and heavy installations, they need to be easy to assemble during manufacturing, but also easy to maintain and repair.

[0004] Another aspect of installing energy storage systems, such as batteries, or other accessories is safety. There is concern about whether the various components installed in or on the vehicle are securely mounted and functioning predictably if the vehicle is involved in an accident. Therefore, safety measures are required for energy storage systems and the like.

[0005] Therefore, there is a need for efficient and reliable solutions for mounting different components of a vehicle during manufacture and repair of the vehicle. The mounting solutions often used today provide a cumbersome process and are quite complex in terms of the installation procedures and mounting arrangements.

[0006] In DE 102 17 009 176, a coupling device for fixing a vehicle component to a frame side member of a vehicle frame is discussed; however, in this solution, a complex alignment of the coupling device is required. Summary of the Invention

[0007] The object of the present invention is to avoid at least some of the above-mentioned disadvantages and to provide an improved system for mounting an energy storage system or other accessory unit to a vehicle frame. It is therefore an object of the present invention to provide a system and method for mounting an energy storage system or an accessory unit to the frame of a heavy vehicle. According to a first aspect of the invention, the object is achieved by a system according to the invention, wherein a mounting system is provided for mounting at least one accessory unit, such as an energy storage system ESS, to a vehicle frame. The mounting system comprises: at least one side channel, which is attached to the accessory unit; at least one screw strip, which comprises a plate, which has a plurality of screws, which are assembled at predetermined positions or intervals, which predetermined positions or intervals are defined by the matching mounting positions of at least one frame-mounted bushing. The screw strip is displaceably assembled in the side channel. The system further comprises at least one mounting bracket arranged to receive screws mounted on the screw strip and to receive a nut for each screw, the nut being arranged to secure the mounting system by pressing the screws towards locking means in the side channels, and wherein the bracket is arranged to receive a frame mounted bushing mounted to a side rail of the vehicle frame. The screw strip provides a low-cost solution for adjusting the position of the accessory unit relative to the frame and the frame mounted bracket.

[0008] If the vehicle decelerates rapidly, the screw strip can provide a friction braking function for the mounting system. The friction braking function can be determined by the number of screws attached to the screw strip or by the mounting force applied to each nut / screw joint of the screws mounted to the at least one frame-mounted bracket. In the event of rapid deceleration of the vehicle, such as in the event of an accident, the braking function provides a more secure and proactive behavior for the accessory unit.

[0009] The mounting system may further include at least two side channels and at least two screw strips. Using two or more channels on each side may provide better alignment, more secure mechanical suspension for the accessory unit, and more controlled behavior of the accessory unit in the event of rapid deceleration. Having two or more side channels provides a mechanically secure solution for mounting large and heavy accessory units to a vehicle.

[0010] The side channel may comprise a plurality of separate segments which are longitudinally attached to each other and together form a continuous length along the at least one accessory unit. The side channel may be provided as an integral part of the accessory unit or may be attached to the side of the accessory unit. By means of the system according to the invention, several segments may be attached and easily handled. The different segments may also be of different accessory types but still be mounted as a single unit. This is advantageous as this provides a highly flexible mounting solution in which different types of accessory units can be mounted to the vehicle using the same mounting system.

[0011] Each channel may comprise a generally U-shaped profile having an inwardly projecting flange that serves as a locking member for the screw strip. The at least one side channel may be formed in an extruded metal profile, such as an extruded aluminum profile. This offers the advantage of a low-cost means for providing the locking function.

[0012] In one example, the accessory unit may be an energy storage system (ESS). The mounting system for an ESS has the advantage of being easy to install during initial installation, but also reduces the complexity of removal and reinstallation in the event of a quick replacement of the energy storage system or repair of the ESS and / or vehicle.

[0013] The mounting system may further comprise a frame mounted bushing arranged to be mounted on a side rail of the vehicle, and wherein the bushing comprises a protruding element arranged to receive the mounting bracket. This has the benefit of easily attaching the mounting bracket to the vehicle.

[0014] In another aspect of the invention, a vehicle is provided comprising a mounting system according to the invention.

[0015] Another aspect of the present invention provides a method for mounting an accessory unit to a vehicle, the method comprising the steps of pre-mounting at least one mounting bracket on at least one screw strip, the at least one screw strip comprising a plurality of screws assembled at predetermined intervals defined by matching mounting positions of at least one frame mounted bushing secured to a side rail mounted to a vehicle frame; sliding each of the at least one screw strip into a corresponding side channel attached to the accessory unit; securing the screw strip to the at least one side channel to secure movement of the screw strip relative to the side channel; and lifting the accessory unit into a position where the mounting bracket (30) rests on the at least one frame mounted bushing. This has the advantage of providing a fast and flexible mounting solution for mounting an accessory unit to a vehicle.

[0016] Further advantages and advantageous features of the invention are disclosed in the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Embodiments of the invention cited as examples will be described in more detail below with reference to the accompanying drawings.

[0018] In the attached figure:

[0019] Figure 1 is a schematic diagram of a vehicle having an installed system;

[0020] Figure 2 is a detailed schematic diagram of a vehicle frame with a mounting system;

[0021] Figure 3 is a detailed schematic three-dimensional view of the installation system;

[0022] Figure 4 is a schematic three-dimensional view of a screw strip;

[0023] Figure 5 is a schematic side sectional view of the mounting system;

[0024] Figure 6 is a schematic installation program for installing the system; and

[0025] Figure 7 is a schematic block diagram illustrating a method of mounting an accessory unit to a vehicle. DETAILED DESCRIPTION

[0026] exist Figure 1In the figure, reference numeral 10 generally shows a heavy vehicle. The example vehicle is shown as a truck for receiving a trailer, but other types of trucks, buses, work machines and construction equipment may also be suitable for the present solution. In this case, the vehicle is equipped with an accessory unit 20, which is attached to the frame 11 of the vehicle. The accessory unit is located between the front wheels 12 and the rear wheels 13 of the vehicle and is mounted to the frame 11 using a mounting system 15. It should be noted that the accessory unit can be located at other locations on the vehicle than between the front and rear wheels. For example, the accessory unit 20 may be an energy storage system (ESS) such as a battery pack, but other types of accessories are also considered to be mounted to the vehicle using the present solution.

[0027] Figure 2 A more detailed view of an accessory unit, such as an energy storage system, is shown mounted to a frame 11 via two side rails 12 using a mounting system 15. The side rails 12 provide a base structure for mounting equipment and accessories to be used on or with the vehicle. An accessory unit 20, such as an ESS, can include a single module or multiple modules 21 that are attached adjacent to each other and together form a continuous unit in the longitudinal direction of the vehicle.

[0028] exist Figure 3 , a more detailed view of the mounting system 15 is shown. The mounting system 15 includes at least one mounting bracket 30 arranged to receive a frame-mounted bushing 50 that is attached to the frame 11 via the frame's side rails 12. The side rails may include a plurality of openings (not shown) for receiving fastening elements, such as screws and nuts, for fastening different types of equipment, such as the frame-mounted bushing 50. The mounting bracket 30 of the accessory unit 20 is arranged to receive the bushing to limit movement of the accessory unit in a horizontal direction; for example, the mounting bracket may include a receiving cavity (not shown) that receives the protruding element 53 of the frame-mounted bushing.

[0029] The mounting system further comprises at least one sliding element for receiving the mounting bracket and fitting in the side channel, thereby providing a flexible and adjustable position of the mounting bracket relative to the frame, i.e., the sliding element can slide in the side channel and be fastened in place in the side channel by a flexible locking element (such as a screw / nut, a self-locking screw or other similar element). Such a receiving element can be, for example, one or more screw strips 40, each of which is attached to the side channel 22, which in turn is an integral part of the accessory unit or is arranged in an element 45, which is attached to the accessory unit as an extruded metal profile (e.g., an extruded metal profile made of aluminum). The side channel runs along the accessory unit for at least part of its length so as to provide appropriate mechanical support for the accessory unit of the vehicle. The side channel comprises a locking device 23 for securing the screw strips to the mounting bracket 30 of the accessory unit, which will be discussed further below.

[0030] The accessory unit is mounted to the frame-mounted bushing by lifting the accessory unit and then lowering it onto the protruding element of the bushing. The mounting bracket may be provided with a receiving element (not shown) that receives the protruding element of the frame-mounted bushing, thereby limiting movement in the horizontal plane. Movement of the accessory unit in the vertical direction may be further limited by some locking mechanism (not shown).

[0031] As in Figure 4 As can be seen in the figure, the screw strip includes an elongated plate 41 having a plurality of screws 42 attached to the screw strip, each screw being arranged to receive a nut 43. These screws are positioned on the screw strip at suitable locations or at suitable intervals for attaching at least one frame-mounted bracket 30 to the frame 11 via the frame's side rails 12. The screws on the screw strip mate with the mounting bracket 30 in openings 31 and are attached to the mounting bracket via nuts 43. When the nuts are tightened, the screws press against the locking devices 23 of the side channels 22, thereby securing the mounting bracket to the accessory unit via the screw strip. For example, the locking devices may comprise a generally U-shaped profile having an inwardly projecting flange with an opening that allows the screws to fit therein and serve as a locking member for the screw strip. The locking devices may be an integral part of the accessory unit or an element attached thereto. It should be noted that in addition to screws and nuts, other fastening means may be used for attaching the screw strip to the mounting bracket.

[0032] Figure 5A side cross-sectional view of a mounting system is shown with an accessory unit 20, such as an energy storage system (ESS), a mounting bracket 30, and a frame-mounted bushing 50. In this case, the accessory unit 20 comprises a plurality of side channels 22, which in this example are located in a separate element 45 attached to the accessory unit. The frame-mounted bushing comprises a bracket for attachment to the side rail 12 of the frame 11 and a protruding element 52, on which the mounting bracket rests. Figure 5 , the locking means 23 are more clearly shown. The side channels 22 are slightly larger than the screw strips, making it easier to slide the screw strips into the side channels and adjust the position of the mounting bracket relative to the frame mounted bushings during installation of the mounting system to the accessory unit.

[0033] The attachment unit (e.g. ESS unit) may comprise several units that are attached to each other and together form a continuous unit, and the side channel may be provided as several units and attached or integrated in the attachment unit, such as to form a continuous channel along the attachment unit for the screw strip to travel along the channel. Figure 6 , wherein several side channels 44 are located in or within a plurality of accessory units 21. Figure 6 A, also shown is a screw strip with mounting brackets made to slide into the side channels to get into position for mounting accessories to the frame ( Figure 6 B) Since the screw strips slide easily along the side channels, they can be easily adjusted to the correct position or spacing for mounting the accessory unit to the vehicle. Figure 6 In the example shown, the accessory unit is a larger and potentially heavier unit, so two combined screw strip / mounting bracket sets are used on each side of the accessory unit to provide a stable and secure mounting solution.

[0034] The longitudinal direction of the side channel can be in the direction of travel of the vehicle, and by controlling the locking stiffness of the screw strips relative to the accessory unit, a controlled mechanical behavior of the accessory unit 20 can be provided in the event of a rapid deceleration, such as in the event of an accident. This can be provided, for example, by controlling the torque applied to the nuts to secure the screws, the number of screws / nuts used for attachment to the mounting bracket, or by providing a controlled frictional behavior between each screw and the locking device 23. Thus, if the vehicle undergoes a rapid deceleration, the accessory unit can be allowed to move relative to the frame in a controlled manner, thereby reducing the direct impact on the overall structure of the vehicle.

[0035] Figure 7 A method of mounting an accessory unit to a vehicle is shown. The method comprises the following steps:

[0036] 701. One or more mounting brackets are pre-installed onto the screw strip at predetermined intervals defined by the mating mounting positions of at least one frame mounted bushing 50 secured to the side rail 12 mounted to the frame 11 of the vehicle. For example, Figure 6 As shown, three screw strips are used on each side of the accessory unit, and a plurality of mounting brackets are attached to the screw strips.

[0037] 702. When the mounting bracket is attached to the screw strip, slide the combined screw strip / mounting bracket into one or more side channels that are attached or integrated into the accessory unit. Figure 6 , one combined set on each side of the accessory unit slides into the corresponding side channel.

[0038] 703. When the screw strip is in position in the side channel, secure the screw strip to the side channel, for example, by tightening the nut 43, thereby pressing the head of the screw 42 toward the locking device 23. In this way, the movement of the mounting bracket and the screw strip is fixed and locked relative to the side channel and the accessory unit.

[0039] 704. In a final step, the accessory unit 20 together with the mounting system is lifted so that the protruding element 53 of the mounting bracket is lifted onto the frame mounted bushing of the vehicle and the mounting bracket is thereby seated on the frame mounted bushing.

[0040] It should be understood that the present invention is not limited to the embodiments described above and shown in the drawings; rather, those skilled in the art will recognize that many changes and modifications are possible within the scope of the appended claims.

Claims

1. A mounting system (15) for mounting at least one accessory unit (20) to a frame (11) of a vehicle (10), characterized in that The mounting system comprises: - at least one side channel (22) attached to the accessory unit; - at least one screw strip (40) comprising a plate having a plurality of screws (42) mounted at predetermined intervals defined by matching mounting positions of at least one frame-mounted bushing (50), wherein the screw strip is displaceably mounted in the side channel; and - at least one mounting bracket (30) arranged to receive the screws assembled on the screw strip and to receive a nut (43) for each screw, the nut (43) being arranged to secure the mounting system by pressing the screw towards a locking device (23) in the side channel (22), and wherein the mounting bracket is arranged to receive a frame-mounted bushing (50) mounted to a side rail (12) of a frame (11) of the vehicle, Wherein, the at least one screw strip is configured to adjust the position of the at least one accessory unit (20) relative to the frame (11) of the vehicle.

2. The mounting system of claim 1, wherein: If the vehicle is rapidly decelerated, the screw strips provide a friction braking function for the mounting system.

3. The mounting system of claim 2, wherein: The friction braking function is determined by the number of screws attached to the screw strip.

4. The mounting system of claim 2, wherein: The friction braking function is determined by the mounting force applied to each nut / screw joint of a screw mounted to the at least one frame mounted bracket.

5. A mounting system according to any preceding claim, wherein: The system includes at least two side channels and at least two screw strips.

6. A mounting system according to any one of claims 1 to 4, wherein: The side channel (22) includes a plurality of segments (44) that are longitudinally attached to one another and together form a continuous length along the at least one accessory unit.

7. A mounting system according to any one of claims 1 to 4, wherein: The side channel is provided as an integral part of the accessory unit or is attached to a side of the accessory unit.

8. A mounting system according to any one of claims 1 to 4, wherein: Each channel comprises a generally U-shaped profile having an inwardly projecting flange serving as a locking member for the screw strip.

9. The mounting system according to any one of claims 1 to 4, wherein: The at least one side channel is formed in an extruded metal profile (45).

10. The mounting system of claim 9, wherein: The metal profile is an aluminum profile.

11. The mounting system according to any one of claims 1 to 4, wherein: The accessory unit is an energy storage system ESS.

12. The mounting system according to any one of claims 1 to 4, further comprising a bushing (50) arranged to be mounted on a side rail (12) of the vehicle, and wherein The bushing includes a protruding element arranged to receive the mounting bracket.

13. A vehicle comprising a mounting system according to any one of claims 1 to 12.

14. A method of mounting an accessory unit (20) to a vehicle (10), the method comprising the steps of: pre-mounting (701) at least one mounting bracket (30) on at least one screw strip (40), the at least one screw strip (40) comprising a plurality of screws assembled at predetermined intervals defined by matching mounting positions of at least one frame-mounted bushing (50), the at least one frame-mounted bushing (50) being secured to a side rail (12) mounted to a frame (11) of the vehicle, • sliding (702) each of the at least one screw strips into a corresponding side channel (22) attached to the accessory unit, securing (703) the screw strip to the at least one side channel to secure movement of the screw strip relative to the side channel, and • Lifting (704) the accessory unit into a position where the mounting bracket (30) rests on the at least one frame mounted bushing (50).

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