Heavy truck battery frame

Abstract

This application relates to the field of battery frame technology, specifically a heavy-duty truck battery frame, comprising an aluminum alloy frame and steel connectors. The aluminum alloy frame includes a top frame, a bottom frame, and side support frames. Both the top frame and the bottom frame include parallelly distributed frame bodies and several longitudinal beams connecting the frame bodies. An annular frame is installed on the outer side of the side support frames. The aluminum alloy frame contains multiple layers of horizontally distributed connecting frames. Each connecting frame includes horizontal beams connecting the side support frames and vertical support beams connecting the top frame and the bottom frame. The horizontal beams are connected by longitudinal beams and are perpendicular to the longitudinal beams. Diagonal braces are provided between the support beams and the side support frames. The steel connectors include a first reinforcing member between the side support frames and the annular frame, and second reinforcing members between the horizontal beams and the side support frames and the support beams, respectively. This application achieves a balance between lightweight and high strength through the combined design of the aluminum alloy frame and steel connectors, adapting to the stress requirements of heavy-duty trucks under complex working conditions and ensuring the safe operation of the battery swapping system.

Description

Technical Field

[0001] This application relates to the field of battery frame technology, and in particular to a heavy-duty truck battery frame. Background Technology

[0002] Battery swapping for new energy heavy-duty trucks has become a trend. The heavy-duty truck battery swapping system mainly includes a battery swapping base installed at the vehicle end and a battery swapping system installed on the battery swapping base. The battery swapping system mainly includes a battery swapping frame and a battery pack fixed in the battery swapping frame, high-voltage box, battery swapping connectors, and other components.

[0003] In actual use, the battery swapping frame is placed on the battery swapping base via a locking mechanism. Because the battery swapping frame itself is relatively tall, generally exceeding one meter, and contains a large number of batteries, it is quite heavy. During driving, the existing steel structure of the battery swapping frame cannot withstand impacts and vibrations from all directions. Utility Model Content

[0004] In order to overcome the problems existing in the prior art, this application provides a heavy truck battery frame.

[0005] The heavy-duty truck battery frame provided in this application adopts the following technical solution:

[0006] A heavy-duty truck battery frame includes an aluminum alloy frame and steel connectors. The aluminum alloy frame includes a top frame, a bottom frame, and side support frames. Both the top frame and the bottom frame include parallelly distributed frame bodies and several longitudinal beams connecting the frame bodies. An annular frame is installed on the outside of the side support frames. The aluminum alloy frame has multiple layers of horizontally distributed connecting frames. Each connecting frame includes horizontal beams connecting the side support frames and vertical support beams connecting the top frame and the bottom frame. The horizontal beams are connected by longitudinal beams and are perpendicular to the longitudinal beams. Diagonal braces are provided between the support beams and the side support frames. The steel connectors include a first reinforcing member connecting the side support frames and the annular frame and a second reinforcing member connecting the horizontal beams and the side support frames and support beams.

[0007] By adopting the above technical solution, the aluminum alloy frame serves as the main structure. The top and bottom frames form stable upper and lower support surfaces through parallel frames and longitudinal beams. The annular frame outside the side support frame enhances overall protection and structural strength. In the multi-layer connecting frame within the aluminum alloy frame, horizontal beams connect the side support frames, and support beams connect the top and bottom frames vertically. The horizontal beams on both sides are connected by longitudinal beams perpendicular to the horizontal beams. The diagonal bracing between the support beams and the side support frames further enhances the frame's torsional and compressive resistance. The first reinforcing member in the steel connector strengthens the connection between the side support frame and the annular frame, while the second reinforcing member stabilizes the connection between the horizontal beams and the side support frames and support beams. This allows the aluminum alloy frame and steel connectors to work together to form a structural system that combines rigidity and flexibility. When the heavy truck is subjected to impacts and vibrations from various directions during operation, the frame effectively disperses and buffers external forces through the cooperation of the multi-directional support structure and reinforcing members, ensuring the safety and stability of components such as the battery pack. At the same time, the lightweight properties of aluminum alloy reduce the overall weight, meeting the usage requirements of the heavy truck battery swapping system.

[0008] Preferably, the side support frame includes horizontally distributed vertical rods and longitudinal beams connecting the vertical rods. A first reinforcing member is installed on the outside of the annular frame for integral connection with the side support frame, and a second reinforcing member is used for connection between the crossbeam and the vertical rods.

[0009] Preferably, the first and second reinforcing members located in the lower half of the heavy truck battery frame are integrally formed.

[0010] By adopting the above technical solution, the side support frame is composed of horizontally distributed vertical rods and longitudinal beams connecting them, forming the side basic support structure. An annular frame is installed on the outside of the side support frame. The first reinforcing member located on the outside of the annular frame is bolted through the annular frame and securely connected to the side support frame, enhancing the overall rigidity of the side. The second reinforcing member tightly connects the crossbeams and vertical rods, improving the structural strength and stability of the frame. In the lower half of the heavy-duty truck battery frame, both the first and second reinforcing members are integrally molded parts. When the heavy-duty truck is subjected to external forces, the first and second reinforcing members, leveraging their integral molding advantage, work in conjunction with the side support frame, annular frame, crossbeams, and other components to evenly distribute the impact force. Simultaneously, this enhances the load-bearing capacity of the lower half of the frame for heavy objects such as the battery pack, effectively resisting vibration and impact, reducing frame deformation, ensuring battery safety, and guaranteeing the stable operation of the battery swapping system.

[0011] Preferably, the density of longitudinal beams distributed between the support beams is greater than the density of longitudinal beams distributed horizontally on both sides, and the top and bottom of the support beams are connected to the middle section of the vertical rods through diagonal braces.

[0012] Preferably, the base frame is also equipped with longitudinally distributed reinforcing beams, which are located on both sides of the support beam and are fixedly connected at the top to the connection between the diagonal brace and the crossbeam.

[0013] By adopting the above technical solution, the densely distributed longitudinal beams between the support beams, compared with the longitudinal beams between the transverse beams on both sides, can more efficiently bear and disperse the vertical pressure from the battery pack and the longitudinal impact force during driving. The top and bottom of the support beams are connected to the middle sections of the transverse beams and vertical rods through diagonal braces, forming a stable triangular structure, which greatly enhances the frame's torsional and compressive resistance and effectively resists lateral external forces. The longitudinally distributed reinforcing beams on the underframe are located on both sides of the support beams, and their tops are fixedly connected to the joints of the diagonal braces and transverse beams, further strengthening the support structure at the bottom of the frame. This allows the entire battery frame to work closely together under complex working conditions such as driving bumps and road impacts, transmitting and dispersing external forces from different directions through the longitudinal beams, diagonal braces, reinforcing beams, and other structures, ensuring the safety and stability of the internal battery pack and extending the service life of the battery frame.

[0014] Preferably, the longitudinal beam is an I-beam, and auxiliary connectors are fixedly connected to both ends of the I-beam. The auxiliary connectors are provided with bolt holes corresponding to those on the side beams and support beams.

[0015] Preferably, the longitudinal beam has several connecting holes evenly distributed along its length.

[0016] By adopting the above technical solution, the longitudinal beams in this battery frame utilize an I-beam structure. Thanks to its unique cross-sectional shape, it can efficiently withstand bending stress and shear force, providing reliable load-bearing capacity for the battery frame. Auxiliary connectors fixed at both ends of the I-beams, through bolt holes corresponding to the crossbeams and support beams on both sides, can quickly and securely achieve bolt connections with these components, enhancing the connection strength and stability between parts. Simultaneously, several connection holes evenly spaced along the length of the longitudinal beams facilitate flexible connection and assembly with other components, allowing for layout adjustments according to actual needs. When the vehicle is subjected to vibration and impact, this structural design enables the longitudinal beams to rapidly disperse external forces to components such as the crossbeams and support beams. The coordinated action of these components effectively buffers and resists external forces, ensuring the stable operation of the battery frame under complex operating conditions and guaranteeing battery safety.

[0017] Preferably, a groove is provided on the outer side of the annular frame, the first reinforcing member is located in the groove, and limiting strips for limiting the first reinforcing member are installed on both inner sides of the groove.

[0018] By adopting the above technical solution, the groove on the outer side of the annular frame provides a precise installation and positioning space for the first reinforcing member. The first reinforcing member is embedded in the groove, achieving a tight fit with the annular frame. Limiting strips installed on the inner surfaces of both sides of the groove limit and fix the first reinforcing member from both sides, effectively preventing displacement due to external forces such as bumps and vibrations during vehicle operation. When a heavy truck encounters complex road conditions and generates impact forces from various directions, the limiting strips and the groove work together to firmly fix the first reinforcing member to the annular frame, ensuring that the first reinforcing member can fully exert its function of enhancing the connection strength between the side support frame and the annular frame, evenly distributing and transmitting the impact force, enhancing the structural stability of the entire battery frame, and ensuring the safe operation of internal components such as the battery pack.

[0019] In summary, this application includes at least one of the following beneficial technical effects:

[0020] 1. This application achieves a balance between lightweight and high strength through the combined design of aluminum alloy frame and steel connectors. The top frame, bottom frame, side support frame and annular frame in the aluminum alloy frame reduce the overall weight, while the first and second reinforcing members in the steel connectors enhance the connection strength of key parts.

[0021] 2. In this application, the horizontal beams and vertical beams of the multi-layer connecting frame are arranged vertically, and together with the support beams and diagonal bracing structure, a three-dimensional support system is formed, which effectively disperses the impact force and vibration in all directions during the driving process; the lower half of the reinforcing member is integrally formed to further improve the structural stability, and the bottom frame reinforcing beam and diagonal bracing work together to enhance the bottom support;

[0022] 3. The longitudinal beams in this application are I-beams with auxiliary connectors and connecting holes, which improves bending strength and facilitates assembly. This structure can adapt to the stress requirements of heavy trucks under complex working conditions, extend the service life of the battery frame, and ensure the safe operation of the battery swapping system. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall structure of the heavy truck battery frame.

[0024] Explanation of reference numerals in the attached drawings: 1. Aluminum alloy frame; 2. Top frame; 21. Frame body; 22. Longitudinal beam; 221. Auxiliary connector; 222. Bolt hole; 223. Connection hole; 3. Base frame; 31. Reinforcing beam; 4. Side support frame; 41. Vertical rod; 5. Circular frame; 51. Groove; 511. Limiting strip; 7. Steel connector; 71. First reinforcing member; 72. Second reinforcing member; 8. Connecting frame; 81. Crossbeam; 82. Support beam; 83. Diagonal brace. Detailed Implementation

[0025] The following is in conjunction with the appendix Figure 1 This application will be described in further detail.

[0026] This application discloses a heavy-duty truck battery frame.

[0027] Reference Figure 1 A heavy-duty truck battery frame includes an aluminum alloy frame 1 and steel connectors 7. The aluminum alloy frame 1 includes a top frame 2, a bottom frame 3, and a side support frame 4. The top frame 2 and the bottom frame 3 each include parallelly distributed frame bodies 21 and several longitudinal beams 22 connecting the frame bodies 21. An annular frame 5 is installed on the outside of the side support frame 4. The aluminum alloy frame 1 has multiple horizontally distributed connecting frames 8. The connecting frames 8 include horizontal beams 81 connecting the side support frames 4 and vertical support beams 82 connecting the top frame 2 and the bottom frame 3. The horizontal beams 81 are connected by longitudinal beams 22 and are perpendicular to the longitudinal beams 22. Diagonal braces 83 are provided between the support beams 82 and the side support frame 4. The steel connectors 7 include a first reinforcing member 71 connecting the side support frame 4 and the annular frame 5 and a second reinforcing member 72 connecting the horizontal beams 81 and the side support frame 4 and the support beams 82. The aluminum alloy frame 1 serves as the main structure. The top frame 2 and bottom frame 3 form stable upper and lower support surfaces through parallel frame bodies 21 and longitudinal beams 22. The annular frame 5 outside the side support frame 4 enhances the overall protection and structural strength. In the multi-layer connecting frame 8 inside the aluminum alloy frame 1, the horizontal beam 81 connects the side support frame 4 horizontally, and the support beam 82 connects the top frame 2 and bottom frame 3 vertically. The horizontal beams 81 on both sides are connected by longitudinal beams 22 perpendicular to the horizontal beams 81. The diagonal brace 83 between the support beam 82 and the side support frame 4 further enhances the frame's torsional and compressive resistance. The steel connector 7... The first reinforcing member 71 strengthens the connection between the side support frame 4 and the annular frame 5, while the second reinforcing member 72 stabilizes the connection between the crossbeam 81 and the side support frame 4 and the support beam 82. This allows the aluminum alloy frame 1 and the steel connecting member 7 to work together to form a structural system that combines rigidity and flexibility. When the heavy truck is subjected to impacts and vibrations from all directions during operation, the frame effectively disperses and buffers external forces through the cooperation of the multi-directional support structure and the reinforcing members, ensuring the safety and stability of components such as the battery pack. At the same time, the lightweight properties of aluminum alloy are used to reduce the overall weight, meeting the usage requirements of the heavy truck battery swapping system.

[0028] Reference Figure 1The side support frame 4 includes horizontally distributed vertical rods 41 and longitudinal beams 22 connecting the vertical rods 41. A first reinforcing member 71 is installed on the outside of the annular frame 5 for integral connection with the side support frame 4, and a second reinforcing member 72 is used to connect the crossbeam 81 to the vertical rods 41. The first reinforcing member 71 and the second reinforcing member 72, located in the lower half of the heavy truck battery frame, are integrally formed. The side support frame 4 is composed of horizontally distributed vertical rods 41 and longitudinal beams 22 connecting them, forming the side basic support structure. The annular frame 5 is installed on the outside of the side support frame 4. The first reinforcing member 71, located on the outside of the annular frame 5, is bolted through the annular frame 5 and firmly connected to the side support frame 4, enhancing the overall rigidity of the side; the second reinforcing member 72 tightly connects the crossbeam 81 to the vertical rods 41, improving the structural strength and stability of the frame. The first reinforcing member 71 and the second reinforcing member 72 in the lower half of the heavy truck battery frame are both integrally molded parts. When the heavy truck is subjected to external force, the first reinforcing member 71 and the second reinforcing member 72, with the advantage of integral molding, work together with the side support frame 4, the ring frame 5, the crossbeam 81 and other components to evenly distribute the impact force. At the same time, they enhance the load-bearing capacity of the lower half of the frame for heavy objects such as battery packs, effectively resist vibration and impact, reduce frame deformation, ensure battery safety, and ensure the stable operation of the battery swapping system.

[0029] Reference Figure 1 The density of the longitudinal beams 22 distributed between the support beams 82 is greater than the density of the longitudinal beams 22 distributed horizontally on both sides between the horizontal beams 81. The top and bottom of the support beams 82 are connected to the middle section of the vertical rod 41 via diagonal braces 83 through the horizontal beams 81. The base frame 3 is also equipped with longitudinally distributed reinforcing beams 31, which are located on both sides of the support beams 82 and whose tops are fixedly connected to the connection between the diagonal braces 83 and the horizontal beams 81. The longitudinal beams 22, densely distributed between the support beams 82, can more efficiently withstand and disperse the vertical pressure from the battery pack and the longitudinal impact force during driving compared to the longitudinal beams 22 between the two side crossbeams 81. The top and bottom of the support beams 82 are connected to the crossbeams 81 and the middle section of the vertical rods 41 through the diagonal braces 83, forming a stable triangular structure, which greatly enhances the frame's torsional and compressive resistance and effectively resists lateral external forces. The longitudinally distributed reinforcing beams 31 on the base frame 3 are located on both sides of the support beams 82, and their tops are fixedly connected to the joints of the diagonal braces 83 and the crossbeams 81, further strengthening the support structure at the bottom of the frame. This allows the entire battery frame to work closely together under complex working conditions such as driving bumps and road impacts, transmitting and dispersing external forces from different directions through the longitudinal beams 22, diagonal braces 83, reinforcing beams 31, and other structures, ensuring the safety and stability of the internal battery pack and extending the service life of the battery frame.

[0030] Reference Figure 1The longitudinal beam 22 is an I-beam, with auxiliary connectors 221 fixedly connected to both ends. The auxiliary connectors 221 have bolt holes 222 corresponding to those on the side crossbeams 81 and support beams 82. The longitudinal beam 22 has several evenly spaced connection holes 223 along its length. The I-beam structure of the longitudinal beam 22 in this battery frame, with its unique cross-sectional shape, can efficiently withstand bending stress and shear force, providing reliable load-bearing capacity for the battery frame. The auxiliary connectors 221 fixed to both ends of the I-beam can quickly and securely bolt to the crossbeams 81 and support beams 82 through the bolt holes 222 corresponding to those on the side crossbeams 81 and support beams 82, enhancing the connection strength and stability between components. Simultaneously, the evenly spaced connection holes 223 along the length of the longitudinal beam 22 facilitate flexible connection and assembly with other components, allowing for layout adjustments according to actual needs. When the vehicle is subjected to vibration and impact, this structural design allows the longitudinal beam 22 to quickly distribute external forces to components such as the cross beam 81 and support beam 82. The components work together to effectively buffer and resist external forces, ensuring the stable operation of the battery frame under complex working conditions and protecting battery safety.

[0031] Reference Figure 1 A groove 51 is provided on the outer surface of the annular frame 5. The first reinforcing member 71 is located in the groove 51, and limiting strips 511 for limiting the first reinforcing member 71 are installed on both inner sides of the groove 51. The groove 51 on the outer side of the annular frame 5 provides a precise installation and positioning space for the first reinforcing member 71. The first reinforcing member 71 is embedded in the groove 51 and fits tightly with the annular frame 5. The limiting strips 511 installed on the inner sides of the groove 51 limit and fix the first reinforcing member 71 from both sides, effectively preventing it from shifting due to external forces such as bumps and vibrations during vehicle operation. When the heavy truck encounters complex road conditions and generates impact forces from all directions, the limiting strips 511 and the groove 51 work together to firmly fix the first reinforcing member 71 on the annular frame 5, ensuring that the first reinforcing member 71 can fully play its role in enhancing the connection strength between the side support frame 4 and the annular frame 5, evenly distributing and transmitting the impact force, enhancing the structural stability of the entire battery frame, and ensuring the safe operation of internal components such as the battery pack.

[0032] Working principle: The aluminum alloy frame 1 forms the main body. Its top frame 2 and bottom frame 3 are connected by parallel frame bodies 21 and longitudinal beams 22 to form the basic structure. A ring-shaped frame 5 is installed on the outside of the side support frame 4. Multiple connecting frames 8 are installed inside the frame. The horizontal beams 81 of the connecting frames 8 horizontally connect to the side support frame 4, and the support beams 82 vertically connect the top frame 2 and the bottom frame 3. The horizontal beams 81 are vertically connected by longitudinal beams 22. Diagonal braces 83 are installed between the support beams 82 and the side support frame 4, forming a stable spatial structure. The first reinforcing member 71 in the steel connector 7 connects the side support frame 4 and the ring-shaped frame 5, and the second reinforcing member 72 connects the horizontal beams 81 to the side support frame 4 and the support beams 82, enhancing the connection strength of each component. The side support frame 4 consists of vertical rods 41 and longitudinal beams 22. The first reinforcing member 71 is installed on the outside of the ring-shaped frame 5 to achieve an overall connection between the ring-shaped frame 5 and the side support frame 4. The second reinforcing member 72 is used to connect the horizontal beams 81 to the vertical rods 41. The first reinforcing member 71 and the second reinforcing member 72, located in the lower half of the heavy truck battery frame, are integrally formed, further improving structural stability. The density of the longitudinal beams 22 between the support beams 82 is greater than that between the transverse beams 81. The top and bottom of the support beams 82 are connected to the middle section of the vertical rod 41 via diagonal braces 83 through the transverse beams 81. The reinforcing beams 31 on the base frame 3 are located on both sides of the support beams 82 and are fixed at the connection points of the diagonal braces 83 and the transverse beams 81, enhancing the frame's resistance to impact and vibration. The longitudinal beams 22 are I-beams, and the auxiliary connecting parts 221 at both ends are connected to the transverse beams 81 and support beams 82 via bolt holes 222. The connecting holes 223 in the length direction can meet different installation requirements. The first reinforcing member 71 in the groove 51 of the annular frame 5 is limited by the limiting strip 511 to ensure reliable connection. The entire frame, through the reasonable combination of aluminum alloy and steel connecting parts 7 and the structural design of each component, adapts to the impact and vibration in all directions during driving, ensuring the stable installation and use of the battery swapping system.

[0033] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A heavy duty truck battery frame, characterized by: Includes an aluminum alloy frame (1) and steel connectors (7); The aluminum alloy frame (1) includes a top frame (2), a bottom frame (3), and a side support frame (4). The top frame (2) and the bottom frame (3) both include parallelly distributed frame bodies (21) and several longitudinal beams (22) connecting the frame bodies (21). An annular frame (5) is installed on the outside of the side support frame (4). The aluminum alloy frame (1) is provided with multiple horizontally distributed connecting frames (8). The connecting frames (8) include horizontal beams (81) that are horizontally connected between the side support frames (4) and support beams (82) that are vertically connected between the top frame (2) and the bottom frame (3). The horizontal beams (81) are connected to each other by longitudinal beams (22) and the horizontal beams (81) are perpendicular to the longitudinal beams (22). Diagonal braces (83) are provided between the support beams (82) and the side support frame (4). The steel connector (7) includes a first reinforcing member (71) connecting the side support frame (4) and the annular frame (5) and a second reinforcing member (72) connecting the crossbeam (81) and the side support frame (4) and the support beam (82).

2. The heavy duty truck battery frame of claim 1, wherein: The side support frame (4) includes horizontally distributed vertical rods (41) and longitudinal beams (22) connecting the vertical rods (41). The first reinforcing member (71) is installed on the outside of the annular frame (5) for integral connection with the side support frame (4), and the second reinforcing member (72) is used for connection between the crossbeam (81) and the vertical rods (41).

3. The heavy duty truck battery frame of claim 2, wherein: The first reinforcing member (71) and the second reinforcing member (72) located in the lower half of the heavy truck battery frame are both integrally formed.

4. The heavy-duty truck battery frame according to claim 1, characterized in that: The density of the longitudinal beams (22) distributed between the support beams (82) is greater than the density of the longitudinal beams (22) between the horizontal beams (81) distributed on both sides, and the top and bottom of the support beams (82) are connected to the middle section of the vertical rod (41) through the horizontal beams (81) via diagonal braces (83).

5. The heavy duty truck battery frame of claim 4, wherein: The base frame (3) is also equipped with longitudinally distributed reinforcing beams (31), which are located on both sides of the support beam (82) and are fixedly connected at the top to the connection between the diagonal brace (83) and the crossbeam (81).

6. The heavy duty truck battery frame of claim 1, wherein: The longitudinal beam (22) is an I-beam, and auxiliary connectors (221) are fixedly connected to both ends of the I-beam. The auxiliary connectors (221) are provided with bolt holes (222) corresponding to the crossbeams (81) and support beams (82) on both sides.

7. The heavy duty truck battery frame of claim 6, wherein: The longitudinal beam (22) has several connecting holes (223) evenly distributed along its length.

8. The heavy duty truck battery frame of claim 2, wherein: A groove (51) is provided on the outer side of the annular frame (5), the first reinforcing member (71) is located in the groove (51), and a limiting strip (511) for limiting the first reinforcing member (71) is installed on both inner sides of the groove (51).

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