A flexible suspended power battery frame for new energy heavy trucks

Abstract

This invention relates to a flexible suspended power battery frame for new energy heavy trucks, solving the problem of power battery failure caused by frequent vibration. It includes a flexible suspension support assembly (1), a power battery support fixing assembly (2), a power battery frame base assembly (3), and a base assembly (4). The flexible suspension support assembly (1) includes a rubber support assembly (11), a power battery frame fixing seat (12), and a power battery fixing support (13). The power battery support fixing assembly (2) includes a suspension support beam (21), an inclined support beam (22), and a vertical support beam (23). The power battery frame base assembly (3) includes a frame base stepped beam (31), a power battery upper frame (32), and an X-shaped beam (33). The base assembly (4) includes a base side beam (41), a base longitudinal beam (42), a base connector (43), a base reinforcing bracket (44), and a frame sub-beam (46). The present invention uses a flexible pad for transition at the connection of the power battery, which is simple in structure, lightweight, and has modular, universal and serialization functions.

Description

Technical Field

[0001] This invention relates to a flexible suspended power battery frame for new energy heavy trucks, belonging to the field of new energy vehicles. Background Technology

[0002] In the field of new energy heavy-duty trucks, the power battery is usually located behind the cab. The power battery is one of the key components of new energy commercial vehicles, accounting for approximately 40% to 60% of the total vehicle cost. Therefore, effective protection mechanisms or measures should be adopted in the design to avoid unnecessary losses for customers. Currently, the power battery frame generally uses a rigid, layered rear frame to fix the power battery, which has problems such as complex structure and heavy weight. Moreover, with the vehicle operating under harsh conditions, vibrations are aggravated, and the rigidly connected power battery is prone to functional failure due to severe vibration. Summary of the Invention

[0003] This invention provides a flexible suspended power battery frame for new energy heavy-duty trucks based on a distributed arrangement of a main frame, which solves the problem of power battery failure caused by frequent vibration. This invention is achieved through the following technical solutions: A flexible suspended power battery frame for new energy heavy trucks includes a flexible suspended support assembly 1, a power battery support fixing assembly 2, a power battery frame base assembly 3, and a base assembly 4. The flexible suspension support assembly 1 includes a rubber support assembly 11, a power battery frame fixing seat 12, and a power battery fixing support 13. The rubber support assembly 11 is fixedly connected between the power battery frame fixing seat 12 and the power battery fixing support 13. The power battery support fixing assembly 2 includes a suspension seat support beam 21, an inclined support beam 22, and an upright support beam 23. The suspension seat support beam 21 and the upright support beam 23 are welded together to form a rectangular grid-like fixing plate. The inclined support beam 22 is placed between the suspension seat support beam 21 and the upright support beam 23 to reinforce the power battery support fixing assembly 2. Two power battery support fixing assemblies 2 are respectively placed in front of and behind the power battery frame base assembly 3. The power battery frame fixing seat 12 is fixedly connected to the suspension seat support beam 21. The power battery frame base assembly 3 includes a frame base stepped crossbeam 31, a power battery upper frame 32, and an X-shaped beam 33. These are welded together with the upright support beam 23 of the power battery support fixing assembly 2 to form a frame structure. The left side of the power battery frame base assembly 3 consists of the frame base stepped crossbeams 31, arranged sequentially from top to bottom to form the power battery installation inlet. The right side of the power battery frame base assembly 3 has an X-shaped beam 33 welded together with the upright support beam 23 of the battery support fixing assembly 2. The X-shaped beam 33 is also constructed of high-strength rectangular steel welded together, reinforcing the main body of the power battery frame base assembly 3. The upper part of the power battery frame base assembly 3 is the power battery upper frame 32, welded from high-strength rectangular steel. The upper part of the power battery upper frame 32 has two lifting bodies: a left lifting body 321 and a right lifting body 322, both of which are frame structures welded from high-strength rectangular steel. The upper part of the base assembly 4 is connected to the power battery support fixing assembly 2 and the power battery frame base assembly 3, and the lower part is connected to the vehicle frame assembly.

[0004] The base assembly 4 includes a base side beam 41, a base longitudinal beam 42, a base connector 43, a base reinforcing bracket 44, and a frame sub-beam 46. All materials involved are high-strength rectangular steel. The base side beam 41, base longitudinal beam 42, base connector 43, and reinforcing bracket 44 are connected to form a base frame. The base connector 43 is welded between the base side beams 41. Two frame sub-beams 46 are welded to the middle of the bottom of the base frame. The base reinforcing bracket 44 is welded between the base side beams 41 above the frame sub-beams 46. A frame reinforcing beam 45 is also welded between the side of the frame sub-beams 46 and the bottom of the base side beams 41. The frame sub-beams 43 have a C-shaped cross-section, which is adapted to the transverse cross-section of the upper wing surface of the frame assembly. In this invention, it is shown as a variable cross-section shape, which is rolled from high-strength steel plate. The frame reinforcing beam 45 is made of high-strength rectangular steel and is welded according to the transition surface of the frame reinforcing beam 45 and the base side beams 41.

[0005] The rubber support assembly 11 includes an upper pad 101, an inner sleeve 102, a rubber pad 103, and a base plate 104. The inner sleeve 102 is connected between the upper pad 101 and the base plate 104, with its two ends respectively embedded between the upper pad 101 and the base plate 104. The rubber pad 103 is vulcanized on the outer cylindrical surface of the inner sleeve 102 and vulcanized and bonded to the upper pad 101 and the base plate 104 respectively. The base plate 104 is elliptical in shape, with a through hole at each end, serving as a screw connection interface for connection with the bolt 15 and the power battery fixing support 13. The power battery frame fixing seat 12 is a ductile iron casting support, which is composed of a straight body 121 and a vertical body 122 in a T-shape. Four reinforcing ribs are provided between the two. A screw-in through hole 123 is provided in the middle of the straight body 121, which is connected to the inner sleeve 102 of the rubber support assembly 11 by fixing bolts 14. The vertical body 122 is provided with two through holes 124 for fixed connection with the suspension seat support beam 21. The power battery fixing support 13 is a ductile iron casting support, consisting of a straight body 131 and a vertical body 132 in a T-shape. Four reinforcing ribs are provided between the two. A large hole is provided in the middle of the straight body 131, which is connected to the inner sleeve 102 of the rubber support assembly 11 by fixing bolts 14. A small hole is provided on each side of the large hole, which is connected to the bottom plate 104 of the rubber support assembly 11 by bolts 15. The vertical body 132 is provided with four through holes 134 for fixing the power battery.

[0006] This invention replaces the traditional rigid frame connection of power batteries with a flexible suspended power battery frame for new energy heavy-duty trucks based on a distributed arrangement of the main frame. It utilizes flexible pads for vibration damping to further mitigate power battery failure caused by frequent and severe vibrations of the vehicle. Compared to traditional rigid rear-mounted power battery frames, it has advantages such as simple structure and light weight; it also features modularity, universality, and serialization. By arranging and using flexible supports, it allows for the combination of different power battery packs with varying capacities to meet customers' actual power usage needs. Attached Figure Description

[0007] Figure 1 Schematic diagram of the structure of this invention; Figure 2 Schematic diagram of the power battery installation in this invention; Figure 3 Schematic diagram of flexible suspension support assembly; Figure 4 Schematic diagram of rubber bearing assembly, wherein Figure b is a top view of Figure a and Figure c is a perspective view; Figure 5 This is a schematic diagram of the power battery frame mounting bracket; Figure 6 This is a schematic diagram of the power battery mounting bracket; Figure 7 This is a schematic diagram of the power battery support mounting assembly; Figure 8 This is a schematic diagram of the power battery installation; Figure 9 This is a schematic diagram of the flexible suspension support assembly installation; Figure 10 This is a schematic diagram of the power battery frame base assembly; Figure 11 ,12 This is a schematic diagram of the base assembly. Detailed Implementation

[0008] like Figure 1-12 As shown, the present invention is a flexible suspended power battery frame for new energy heavy trucks, mainly comprising: a flexible suspended support assembly 1, a power battery support fixing assembly 2, a power battery frame base assembly 3, and a base assembly 4, wherein the power battery support fixing assembly 2 has two bases.

[0009] The flexible suspension support assembly 1 is mainly composed of rubber support assembly 11, power battery frame fixing seat 12, power battery fixing support 13, fixing bolt (with nut) 14, and bolt (with nut) 15.

[0010] The rubber support assembly 11 mainly consists of an upper pad 101, an inner sleeve 102, a rubber pad 103, and a base plate 104. As a core vibration damping component of the flexible suspended power battery frame, it mainly bears the force or torque from the vibration of the power battery. The upper pad 101 is a high-strength steel circular pad, and the inner sleeve 102 is a cylindrical body with a through hole in the middle. The two are welded together to form a T-shaped body. The upper pad 101 and the upper surface of the inner sleeve 102 of the T-shaped body are welded smoothly and without burrs. They are connected and fixed to the power battery frame fixing seat 12 by fixing bolts (with nuts) 14. The T-shaped body and the rubber pad 103 are bonded together by vulcanization. The bottom plate 104 is the bottom support structure of the rubber support assembly 11 and is bonded to the rubber pad 103 by vulcanization. The bottom plate 104 is elliptical in shape with a through hole at each end, which serves as a screw interface for connection with the bolt (with nut) 15 and the power battery fixing support 13. The whole structure constitutes a vibration-damping floating structure.

[0011] The power battery frame mounting base 12 is a ductile iron casting support, mainly composed of a straight body 121 and a vertical body 122, with four reinforcing ribs between them to enhance the load-bearing capacity of the main support. The power battery frame mounting base 12 is used to connect and fix the rubber support assembly 11 and the suspension seat support beam 21. This support has a T-shaped design. The upper and lower sides of the straight body 121 require machining to control surface precision, and a threaded through hole 123 is provided in the middle for connection to the rubber support assembly 11 via fixing bolts 14. The vertical body 122 has two through holes 124 for fixed connection to the suspension seat support beam 21. The area near the bolt heads in the through holes 124 and the contact surface of the suspension seat support beam 21 are machined to control surface precision, ensuring reliable bolt fixing connections.

[0012] The power battery mounting bracket 13 is a ductile iron casting bracket, mainly composed of a straight body 131 and a vertical body 132, with four reinforcing ribs between them to enhance the load-bearing capacity of the main body bracket. The power battery mounting bracket 13 is used to connect and fix the rubber bracket assembly 11 to the power battery body. This bracket has a T-shaped design. The upper and lower sides of the straight body 131 require machining to control surface precision. A large hole and two small holes, totaling three bolted through holes 133, are provided in the middle, which are connected to the rubber bracket assembly 11 by fixing bolts 14 and 15. The vertical body 132 has four through holes 134 for fixing to the power battery. The area near the bolt heads of the through holes 134 and the surface in contact with the power battery are machined to control surface precision, ensuring reliable bolt fixing.

[0013] The power battery support fixing assembly 2 is mainly composed of a suspension seat support beam 21, an inclined support beam 22, and an upright support beam 23.

[0014] The suspension seat support beam 21 is made of high-strength rectangular steel, and its length must not exceed the vehicle width requirement, i.e., less than 2550mm. Six holes are provided on the suspension seat support beam 21, and six welding nuts are pre-embedded inside the steel corresponding to these six holes for bolt connection with the vertical body 122. This invention demonstrates the fixing of four layers of power batteries. Correspondingly, four sets of suspension seat support beams 21 are arranged in the power battery support fixing assembly 2, and welded together with four sets of upright support beams 23 to form a rectangular grid-like fixing plate. An inclined support beam 22 is placed between the suspension seat support beams 21 and the upright support beams 23 to reinforce the power battery support fixing assembly 2. A flexible suspended power battery frame for a new energy heavy truck requires two power battery support fixing assemblies 2, one in front and one behind the power battery frame base assembly 3.

[0015] The power battery frame base assembly 3 is mainly composed of the frame base stepped crossbeam 31, the power battery upper frame 32, and the X-shaped beam 33.

[0016] The power battery frame base assembly 3 is a frame structure welded together from high-strength rectangular steel sections. The left side of the power battery frame base assembly 3 consists of four sets of stepped crossbeams 31 arranged from top to bottom, serving as the power battery installation inlet. The right side of the power battery frame base assembly 3 is welded together with X-shaped beams 33, which are also constructed from high-strength rectangular steel sections welded together, reinforcing the main body of the power battery frame base assembly 3. The upper part of the power battery frame base assembly 3 is the upper power battery frame 32, welded together from high-strength rectangular steel sections. The upper power battery frame 32 has two lifting bodies: a left lifting body 321 and a right lifting body 322, both of which are frame structures welded together from high-strength rectangular steel sections.

[0017] The base assembly 4 includes a base side beam 41, a base longitudinal beam 42, a base connector 43, a base reinforcing bracket 44, and a frame sub-beam 46. All materials involved are high-strength rectangular steel. The base side beam 41, base longitudinal beam 42, base connector 43, and reinforcing bracket 44 are connected to form a base frame. The base connector 43 is welded between the base side beams 41. Two frame sub-beams 46 are welded to the middle of the bottom of the base frame. The base reinforcing bracket 44 is welded between the base side beams 41 above the frame sub-beams 46. A frame reinforcing beam 45 is also welded between the side of the frame sub-beams 46 and the bottom of the base side beams 41. The frame sub-beams 43 have a C-shaped cross-section, which is adapted to the transverse cross-section of the upper flange of the frame assembly. This invention shows a variable cross-section shape, which is rolled from high-strength steel plate. The frame reinforcing beam 45 is made of high-strength rectangular steel and is welded according to the transition surface of the frame reinforcing beam 45 and the base side beams 41.

[0018] The flexible suspended power battery frame for new energy heavy trucks of this invention mainly consists of at least six (24 in this embodiment) flexible suspension support assemblies 1 connected to the power battery support fixing assembly 2 by bolts. The power battery fixing supports 13 in the flexible suspension support assembly 1 are connected to the power battery by bolts. The power battery support fixing assembly 2 is fixed to the power battery frame base assembly 3 by welding. The power battery frame base assembly 3 is welded to the base assembly 4 to form the final battery frame.

[0019] The flexible suspended power battery frame for this new energy heavy truck can be modularized and serialized for expansion and combination. By adding or removing the rubber support assembly 11, the inclined support beam 22, the suspension seat support beam 21, and the frame base stepped beam 31, and by changing the length of the inclined support beam 22, the upright support beam 23, and the X-shaped beam 33, power batteries can be laid in three layers of the frame (2, 4, and 6), achieving a tiered combination of different capacities for the same PACK, and covering the capacity from small to large.

[0020] Finally, it should be noted that the above technical solutions of the present invention have been described in detail, but this is not intended to limit them. Any modifications to the foregoing technical solutions, or equivalent substitutions or improvements to some or all of the features, should be included within the protection scope of the present invention.

Claims

1. A flexible suspended power battery frame for new energy heavy trucks, characterized in that: Including flexible Suspension support assembly (1), power battery support fixing assembly (2), power battery frame base assembly (3) and base assembly (4); The flexible suspension support assembly (1) includes a rubber support assembly (11), a power battery frame fixing seat (12), and a power battery fixing support (13). The rubber support assembly (11) is fixedly connected between the power battery frame fixing seat (12) and the power battery fixing support (13). The power battery support fixing assembly (2) includes a suspension seat support beam (21), an inclined support beam (22), and an upright support beam (23); the suspension seat support beam (21) and the upright support beam (23) are welded together to form a rectangular grid-like fixing plate; the inclined support beam (22) is placed between the suspension seat support beam (21) and the upright support beam (23) to reinforce the power battery support fixing assembly (2); two power battery support fixing assemblies (2) are respectively placed in front of and behind the power battery frame base assembly (3); the power battery frame fixing seat (12) is fixedly connected to the suspension seat support beam (21); The power battery frame base assembly (3) includes a frame base stepped crossbeam (31), a power battery upper frame (32), and an X-shaped beam (33), which are welded together with the vertical support beam (23) of the power battery support fixing assembly (2) to form a frame structure. The left side of the power battery frame base assembly (3) is the frame base stepped crossbeam (31), which are arranged from top to bottom to form the power battery installation inlet. The right side of the power battery frame base assembly (3) is the X-shaped beam (33), which is welded together with the vertical support beam (23) of the power battery support fixing assembly (2) to reinforce the body of the power battery frame base assembly (3). The upper part of the power battery frame base assembly (3) is the power battery upper frame (32), which is welded from high-strength rectangular steel. The upper part of the base assembly (4) is connected to the power battery support fixing assembly (2) and the power battery frame base assembly (3), and the lower part is connected to the vehicle frame assembly.

2. The flexible suspended power battery frame for new energy heavy trucks according to claim 1, characterized in that: The X-shaped beam (33) of the power battery frame base assembly (3) is composed of high-strength rectangular steel cross-welded together.

3. The flexible suspended power battery frame for new energy heavy trucks according to claim 1, characterized in that: The power battery frame base assembly (3) has two lifting bodies on its upper part, namely the left lifting body (321) and the right lifting body (322), both of which are frame structures welded from high-strength rectangular steel.

4. The flexible suspended power battery frame for new energy heavy trucks according to claim 1, characterized in that: The base assembly (4) includes a base side beam (41), a base longitudinal beam (42), a base connector (43), a base reinforcing bracket (44), and a frame sub-beam (46). All of the materials involved are rectangular steel. The base side beam (41), the base longitudinal beam (42), the base connector (43), and the base reinforcing bracket (44) are connected to form a base frame. The base connector (43) is welded between the base side beams (41). Two frame sub-beams (46) are welded to the middle of the bottom of the base frame. The base reinforcing bracket (44) is welded between the base side beams (41) above the frame sub-beams (46). A frame reinforcing beam (45) is also welded between the side of the frame sub-beam (46) and the bottom of the base side beam (41). The frame sub-beam (46) is C-shaped and is adapted to the transverse cross section of the upper wing surface of the frame assembly.

5. A flexible suspended power battery frame for new energy heavy trucks according to claim 4, characterized in that: The sub-beam (46) of the frame has a variable cross-section and is made of high-strength steel plate by roll forming.

6. A flexible suspended power battery frame for new energy heavy trucks according to claim 4, characterized in that: The frame reinforcement beam (45) is made of rectangular steel.

7. A flexible suspended power battery frame for new energy heavy trucks according to claim 1, characterized in that: The rubber support assembly (11) includes an upper pad (101), an inner sleeve (102), a rubber pad (103), and a base plate (104). The inner sleeve (102) is connected between the upper pad (101) and the base plate (104), with its two ends embedded between the upper pad (101) and the base plate (104), respectively. The rubber pad (103) is vulcanized on the outer cylindrical surface of the inner sleeve (102) and vulcanized and bonded to the upper pad (101) and the base plate (104), respectively. The base plate (104) is elliptical in shape, with a through hole at each end, which serves as a screw connection interface for connection with the bolt (15) and the power battery fixing support (13). The power battery frame fixing seat (12) is composed of a straight body (121) and a vertical body (122), and has a T-shaped shape. A screw-in through hole (123) is provided in the middle of the straight body (121), which is connected to the inner sleeve (102) of the rubber support assembly (11) by fixing bolts (14). The vertical body (122) is provided with two through holes (124) for fixed connection with the suspension seat support beam (21). The power battery fixing support (13) is a ductile iron casting support, consisting of a straight body (131) and a vertical body (132), which is T-shaped. Four reinforcing ribs are set between the two. A large hole is set in the middle of the straight body (131), which is connected to the inner sleeve (102) of the rubber support assembly (11) by fixing bolts (14). A small hole is set on each side of the large hole, which is connected to the bottom plate (104) of the rubber support assembly (11) by bolts (15). The vertical body (132) is set with four through holes (134) for fixing the power battery.

8. A flexible suspended power battery frame for new energy heavy trucks according to claim 7, characterized in that: The power battery frame fixing seat (12) is a ductile iron casting support, with four reinforcing ribs between the straight body (121) and the vertical body (122).

9. A flexible suspended power battery frame for new energy heavy trucks according to claim 1, characterized in that: The flexible suspension support assembly (1), the power battery support fixing assembly (2), the power battery frame base assembly (3), and the base assembly (4) are modularly designed.

Images