A mining truck battery box

Abstract

This utility model discloses a mining truck battery box, including a front beam, a rear beam, and side beams. There are two side beams, which are arranged opposite each other. The front beam and the rear beam are located at the two ends of the two side beams, respectively. The side beams include side frames and liquid-cooled base plates. The mining truck battery box of this utility model achieves the development of fewer parts and has the advantages of high welding quality, high structural strength, and good flow channel sealing performance.

Description

Technical Field

[0001] This utility model belongs to the field of mining truck battery boxes, specifically, this utility model relates to a mining truck battery box body. Background Technology

[0002] With the continuous development of new energy in the mining truck market, the harsh environment of mining areas, such as gravel roads and dirt roads, places high demands on the structural strength of battery boxes, including their shock resistance. Traditional battery boxes can no longer meet the requirements of heavy-duty trucks in mining areas, necessitating the continuous development of reinforced battery boxes for mining trucks.

[0003] Mining trucks operate in harsh conditions within the new energy power sector, demanding higher standards for battery box structural strength and sealing. Traditional power battery boxes typically consist of five profiles: a liquid-cooled base plate, front and rear side beams, and left and right side beams. These components are insufficient to meet the structural strength requirements of mining operations, while simultaneously satisfying the airtightness requirements of the liquid-cooling channels. Furthermore, most require welding to the left and right side beams for mounting and other components, resulting in relatively high mold and material costs and a more complex manufacturing process.

[0004] Utility model patent CN220963592U, published on May 14, 2024, discloses a mining truck rear battery box and a new energy mining truck. The box includes a support frame assembly. Along the driving direction, the support frame assembly includes a symmetrically arranged front and rear protective frame, connected by multiple load-bearing beams. Both the rear and front protective frames include a vertically connected first crossbeam and a first vertical beam. The first crossbeam is located at the bottom, and a first supporting diagonal rod is provided between the lower end of the first crossbeam and the first vertical beam. The first vertical beam of the rear protective frame is connected to the upper end of a second supporting diagonal rod, and the lower end of the second supporting diagonal rod can be connected to the longitudinal beam of the vehicle frame. However, this mining truck rear battery box does not solve the aforementioned technical problems. Utility Model Content

[0005] The purpose of this utility model is to address the shortcomings of existing technologies by providing a mining truck battery box that features reduced component development, high welding quality, high structural strength, and reliable flow channel sealing performance.

[0006] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0007] The mining truck battery box includes a front beam, a rear beam, and side beams. There are two side beams, which are arranged opposite each other. The front beam and the rear beam are located at the two ends of the two side beams, respectively. Each side beam includes a side frame and a liquid-cooled base plate.

[0008] The two liquid-cooled base plates are welded together. The front beam end is provided with a first protrusion, and the rear beam end is provided with a second protrusion. One end of the liquid-cooled base plate is provided with a first groove corresponding to the first protrusion, and the other end is provided with a second groove corresponding to the second protrusion. The first protrusion is welded to the first groove of the two liquid-cooled base plates, and the second protrusion is welded to the second groove of the two liquid-cooled base plates.

[0009] The length of the side frame is greater than the length of the liquid-cooled base plate. The bottom sides of the front beam are welded to one end of the two side frames respectively, and the bottom sides of the rear beam are welded to the other end of the two side frames.

[0010] The front beam, rear beam, and top of the side frame are all provided with flanges, and connecting holes are evenly distributed on the flanges.

[0011] Both the front and rear beams are equipped with module mounting beams.

[0012] Two water nozzles are connected to the outer side of the front beam.

[0013] The front beam, rear beam, and side beams are all made of aluminum profiles.

[0014] The technical advantages of this utility model are as follows: The mining truck battery box of this utility model, through the rational design of the front beam, rear beam and side beam, has a simplified design and can achieve the effect of fewer parts development. It improves the welding process between parts, improves the welding quality, reduces the mold opening cost of traditional liquid cooling channels, and correspondingly greatly reduces the raw material cost. The welding equipment used is conventional equipment in the industry, which can optimize the welding process accordingly. It can ensure the overall sealing of the flow channel and welding position of this battery box, thereby meeting the structural strength and sealing performance of the mining truck battery box. It is suitable for the application scenarios of mining trucks in the field of power new energy where the working conditions are relatively harsh. Attached Figure Description

[0015] This manual includes the following figures, which illustrate the following:

[0016] Figure 1 This is an exploded view of the battery box for mining trucks according to this utility model;

[0017] Figure 2 This is a top view of the welding of the left and right side beams of this utility model.

[0018] Figure 3 This is a bottom view of the welding of the left and right side beams of this utility model.

[0019] Figure 4 This is a top view of the welding of the front beam and the rear beam of this utility model;

[0020] Figure 5 This is a bottom view of the welding of the front beam and the rear beam of this utility model.

[0021] The markings in the diagram are as follows: 1. Front beam; 2. Rear beam; 3. Side beam; 4. Side frame; 5. Liquid-cooled base plate; 6. First protrusion; 7. Second protrusion; 8. First groove; 9. Second groove; 10. Flanged edge; 11. Connecting hole; 12. Module mounting beam; 13. Water nozzle. Detailed Implementation

[0022] The specific embodiments of this utility model will be further described in detail below with reference to the accompanying drawings, in order to help those skilled in the art to have a more complete, accurate and in-depth understanding of the inventive concept and technical solution of this invention, and to facilitate its implementation.

[0023] like Figure 1 As shown, the mining truck battery box includes a front beam 1, a rear beam 2, and a side beam 3. There are two side beams 3, which are arranged opposite each other. The front beam 1 and the rear beam 2 are located at the two ends of the two side beams 3, respectively. The side beam 3 includes a side frame 4 and a liquid-cooled base plate 5.

[0024] The main body of the battery box is composed of left side beam 3, right side beam 3, front side beam 1, and rear side beam 2 welded together. Two side frames 4 and two liquid-cooled base plates 5 are provided, with the two side frames 4 serving as the two side panels of the battery box. The main body of the liquid-cooled flow channel is formed by friction stir welding (FSW welding) of the two liquid-cooled base plates 5 of the left and right side beams 3. The formation of the overall flow channel and the connection of the inlet and outlet water pipes are completed by performing local CNC machining on the components after welding the left and right side beams 3, and then welding them to the front and rear side beams 1 and 2. The side frames 4 and the liquid-cooled base plates 5 are an integral structure, meaning that only four profiles are designed around the battery box, simplifying the design and achieving the goal of fewer components. The components are connected by welding, which greatly reduces processing costs while meeting high structural strength requirements, effectively meeting design requirements and making the product more competitive in the market.

[0025] like Figure 1As shown, two liquid-cooled base plates 5 are welded together. The front beam 1 has a first protrusion 6 at its end, and the rear beam 2 has a second protrusion 7 at its end. One end of each liquid-cooled base plate 5 has a first groove 8 corresponding to the first protrusion 6, and the other end has a second groove 9 corresponding to the second protrusion 7. The first protrusion 6 is welded to the first groove 8 of the two liquid-cooled base plates 5, and the second protrusion 7 is welded to the second groove 9 of the two liquid-cooled base plates 5. The protruding ends extend into the grooves, ensuring accurate positioning of the front beam 1 and rear beam 2 with the liquid-cooled base plates 5, improving welding convenience, increasing the welding area, optimizing the welding process quality of friction stir welding, and ensuring reliable welding sealing. The width and length of the first groove 8 and the first protrusion 6 are matched, and the length of the second protrusion 7 is matched with the length of the second groove 9. The cross-sectional width of the second groove 9 is larger than the cross-sectional width of the protrusion on the rear beam 2, allowing the liquid cooling channels on the two liquid-cooled base plates 5 to connect.

[0026] like Figure 1 As shown, the length of the side frame 4 is greater than the length of the liquid-cooled base plate 5. The bottom sides of the front beam 1 are welded to one end of each of the two side frames 4, and the bottom sides of the rear beam 2 are welded to the other ends of each of the two side frames 4. The front beam 1, rear beam 2, and side beam 3 are all L-shaped structures. This design forms the enclosure structure with only four components. The sides of the front beam 1 and rear beam 2 are connected to the liquid-cooled base plate 5 by friction stir welding, and the sides of the front beam 1 and rear beam 2 are connected to the side frames 4 by arc welding. The two ends of the protrusions are arc-shaped and connected by friction stir welding, so that the welding areas of the front beam 1, rear beam 2, and the two side beams 3 form a whole, improving the welding quality and increasing the structural strength.

[0027] like Figure 1 As shown, the front beam 1, rear beam 2, and side frame 4 are all provided with flanges 10 at their tops, and connecting holes 11 are evenly distributed on the flanges 10. The flanges 10 improve the structural strength of the top part of the above components, and at the same time form a connecting plane with the battery cover, thereby achieving a stable connection with the battery cover.

[0028] like Figure 1 As shown, both the front beam 1 and the rear beam 2 are equipped with module mounting beams 12. The module mounting beams 12 are used to connect and fix the battery modules to the housing.

[0029] like Figure 1As shown, two water nozzles 13 are connected to the outer side of the front beam 1. The front beam 1 has internal channels connecting the water nozzles 13 to the liquid cooling channel. When welding the front and rear beams 2 to the liquid cooling base plate 5, the structural strength of the housing and the sealing of the channel, as well as the sealing of the housing frame, must be considered simultaneously. Therefore, when welding the front and rear beams 2 to the components, friction stir welding is used at the bottom channel position, with complete penetration at the corners to ensure the channel sealing. Arc welding is used at the frame position to achieve the sealing of the housing frame. This advantage lies in achieving the sealing of the battery housing using an optimized welding method based on conventional welding equipment, while also offering significant cost advantages, low manufacturing difficulty, and meeting the design requirements for high-strength, high-sealing battery housings in heavy-duty mining truck applications. It can be widely applied to other new energy fields.

[0030] Front beam 1, rear beam 2, and side beam 3 are all made of aluminum profiles. The use of aluminum profiles in the above structure is to reduce weight and material costs.

[0031] The welding and assembly process of the mining truck battery box is as follows: Before welding, each part needs to be sawed, CNC machined, deburred, cleaned, and inspected on the profile substrate according to the drawing requirements before the next welding operation can be carried out.

[0032] First, after positioning the left side beam 3 and the right side beam 3, perform front-side FSW welding, followed by grinding, and then perform reverse-side FSW welding, followed by grinding. In this process, it is necessary to ensure flatness control and internal cavity width control, i.e., complete the welding on the front side (e.g., ...). Figure 2 After that, before welding the reverse side, add reverse deformation, preset the deformation amount to 2mm, and ensure that the welding on both sides is successful (e.g., Figure 3 The direction and speed are the same.

[0033] After the left and right liquid-cooled base plates 5 are welded, necessary CNC machining is performed to process the mating holes of the water nozzle 13, the mating contour of the plug strip, and the flow channel features on both sides.

[0034] Welding of the front and rear side beams 2, such as Figure 4 and Figure 5 As shown, FSW (Friction Stir Welding) welding should be performed on both sides first, followed by arc welding. The key to this process is ensuring complete penetration during FSW welding at the four corners, and the weld height on the sides of the liquid-cooled base plate 5 must be controlled within 2mm. The FSW weld pressure should be less than 0.3mm, and the FSW weld and TIG weld should overlap and cover each other. This operation ensures the airtightness of the overall liquid-cooled flow channel and the welded area of ​​the housing.

[0035] This mining truck battery box features a streamlined design through the rational design of the front beam 1, rear beam 2, and side beam 3, which facilitates development with fewer parts. It improves the welding process between components, enhances welding quality, and reduces the mold opening costs associated with traditional liquid-cooled flow channels, thereby significantly lowering raw material costs. The welding equipment used is industry-standard, enabling optimization of the welding process and ensuring the overall sealing of the flow channels and welding positions of the battery box. This meets the structural strength and sealing performance requirements of mining truck battery boxes, making them suitable for harsh operating conditions in the field of new energy power.

[0036] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the inventive concept and technical solution of the present invention; or the direct application of the inventive concept and technical solution to other situations without modification, are all within the protection scope of the present invention.

Claims

1. A mine truck battery box, characterized by: It includes a front beam (1), a rear beam (2) and a side beam (3). There are two side beams (3), which are arranged opposite to each other. The front beam (1) and the rear beam (2) are located at the two ends of the two side beams (3). The side beam (3) includes a side frame (4) and a liquid-cooled base plate (5).

2. The battery case for a mining truck according to claim 1, characterized in that: The two liquid-cooled base plates (5) are welded together. The front beam (1) has a first protrusion (6) at its end and the rear beam (2) has a second protrusion (7) at its end. One end of the liquid-cooled base plate (5) has a first groove (8) corresponding to the first protrusion (6) and the other end has a second groove (9) corresponding to the second protrusion (7). The first protrusion (6) is welded to the first groove (8) of the two liquid-cooled base plates (5) and the second protrusion (7) is welded to the second groove (9) of the two liquid-cooled base plates (5).

3. The battery case for a mining truck according to claim 2, characterized in that: The length of the side frame (4) is greater than the length of the liquid-cooled base plate (5). The bottom sides of the front beam (1) are welded to one end of the two side frames (4) respectively, and the bottom sides of the rear beam (2) are welded to the other end of the two side frames (4).

4. A battery case for a mining truck according to any one of claims 1-3, characterized in that: The front beam (1), rear beam (2) and side frame (4) are all provided with flanges (10) at the top, and connecting holes (11) are evenly distributed on the flanges (10).

5. The battery case for a mining truck according to claim 4, characterized in that: Both the front beam (1) and the rear beam (2) are equipped with module mounting beams (12).

6. The battery case for a mining truck according to claim 5, characterized in that: Two water nozzles (13) are connected to the outside of the front beam (1).

7. The battery case for a mining truck according to claim 4, characterized in that: The front beam (1), rear beam (2) and side beam (3) are all made of aluminum profiles.

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