A lightweight commercial vehicle battery frame bracket assembly

Abstract

This utility model discloses a lightweight commercial vehicle battery frame bracket assembly, comprising a main frame made of aluminum alloy profiles, a hollow base plate structure disposed at the bottom of the main frame, an elastic limiting block disposed on the inner side of the main frame, a clamping rod assembly movably connected to the top of the main frame, and an integrated mounting bracket disposed on the outside of the main frame for connection with the vehicle frame longitudinal beams; the main frame includes four frame profiles and four corner connectors bolted together; the cross-section of the frame profiles is a hollow cavity structure with multiple reinforcing ribs. This utility model achieves significant weight reduction through structural innovation and material optimization, while ensuring excellent load-bearing capacity, vibration resistance, and durability.

Description

Technical Field

[0001] This utility model relates to the field of commercial vehicle parts technology, and in particular to a lightweight commercial vehicle battery frame bracket assembly. Background Technology

[0002] Currently, in existing technologies, commercial vehicles, especially heavy-duty trucks and buses, are typically equipped with large and heavy batteries to meet the needs of long-term, long-distance operation. The battery frame assembly is a key component for securing the battery, and its performance directly affects the reliability and safety of the vehicle.

[0003] Traditional commercial vehicle battery brackets are mostly made of thick steel plates through stamping and welding, resulting in a bulky structure to meet sufficient strength and rigidity requirements. This structure has the following main disadvantages: 1. High weight: The extensive use of steel leads to an excessively heavy bracket assembly, which does not conform to the trend of lightweighting in automobiles, increases the overall vehicle weight, and leads to increased fuel or electricity consumption, hindering energy conservation and emission reduction. 2. Low material utilization: Traditional stamping and welding structures often have material redundancy, with overall thickening for localized strength, leading to increased costs and resource waste. 3. Poor corrosion resistance: Ordinary steel components are prone to rust under harsh working conditions, affecting service life and aesthetics. 4. Poor design flexibility: Welded structures are difficult to optimize for complex topologies, limiting further lightweight design.

[0004] Therefore, there is an urgent need in the field for a battery frame bracket assembly that can significantly reduce its weight while ensuring sufficient structural strength and rigidity, and also has good corrosion resistance and processability. Utility Model Content

[0005] The technical problem to be solved by this utility model is to overcome the shortcomings of the prior art and provide a lightweight commercial vehicle battery frame bracket assembly. Through structural innovation and material optimization, it achieves a significant lightweight effect while ensuring excellent load-bearing capacity, vibration resistance and durability.

[0006] To solve the above-mentioned technical problems, the technical solution of this utility model is as follows: A lightweight commercial vehicle battery frame bracket assembly includes a main frame made of aluminum alloy profiles, a hollow base plate structure disposed at the bottom of the main frame, an elastic limiting block disposed on the inner side of the main frame, a clamping rod assembly movably connected to the top of the main frame, and an integrated mounting bracket disposed on the outside of the main frame for connection with the vehicle frame longitudinal beam. The main frame includes four frame profiles and four corner connectors that are bolted together with each other. The cross-section of the frame profile is a hollow cavity structure with multiple reinforcing ribs.

[0007] Furthermore, the base plate structure is a stamped aluminum alloy plate.

[0008] Furthermore, the base plate structure has multiple weight-reducing holes and multiple upward-protruding reinforcing plates.

[0009] Furthermore, the reinforcing plate is wavy in shape.

[0010] Furthermore, the clamping rod assembly includes a quick-release clamping rod, an eccentric wheel locking structure, and connecting seats fixed to both sides of the main frame; One end of the quick-release pressure rod and the eccentric wheel locking structure are respectively hinged to the connecting seats on both sides. The quick-release pressure rod and the eccentric wheel locking structure can lock and clamp together to press the battery.

[0011] Furthermore, the integrated mounting bracket and the main frame are integrally formed or welded together.

[0012] Furthermore, the integrated mounting bracket has an elongated hole for connecting to the vehicle frame.

[0013] Furthermore, the corner connector is a cast aluminum alloy part.

[0014] Furthermore, the aluminum alloy profile is made of 6005A or 6061 grade aluminum alloy, and its surface has undergone anodizing treatment.

[0015] Furthermore, the various components of the main frame are connected using a friction stir welding process.

[0016] By adopting the above technical solution, this utility model has the following beneficial effects: 1. This utility model has a significant lightweight effect. It uses high-strength aluminum alloy to replace traditional steel and combines hollow profiles, hollow bottom plates and other structural designs to reduce the weight of the assembly by 40%-50% compared with traditional steel structures, effectively reducing the energy consumption of the whole vehicle.

[0017] 2. This utility model, through its hollow cavity structure and reinforcing rib design, achieves lightweight while ensuring structural rigidity and strength, effectively supporting the battery and suppressing deformation during vehicle vibrations. Friction stir welding and bolt connections ensure the reliability and stability of the connections.

[0018] 3. This utility model has good durability. The aluminum alloy material and surface treatment such as anodizing give the assembly excellent corrosion resistance and extend its service life in harsh environments.

[0019] 4. This utility model achieves both quick-release and battery-locking stability through the engagement of the quick-release pressure rod and the eccentric wheel locking structure.

[0020] 5. The integrated mounting bracket of this utility model simplifies the assembly process, and the quick-release pressure bar assembly makes the installation and removal of the battery more convenient and improves maintenance efficiency.

[0021] 6. This utility model uses a frame profile designed as a hollow cavity structure with multiple reinforcing ribs, and multiple weight-reducing holes and multiple upward-protruding reinforcing ribs on the bottom plate structure, which can achieve both lightweight design and ensure structural strength.

[0022] The above description is merely an overview of the technical solutions of the embodiments of this application. In order to better understand the technical means of the embodiments of this application and to implement them in accordance with the contents of the specification, and to make the above and other objects, features and advantages of the embodiments of this application more obvious and understandable, specific implementation methods of this application are described below. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall structure of an embodiment of the present utility model; Figure 2 This is a side view of an embodiment of the present utility model; Figure 3 This is a schematic diagram of the internal structure of the main frame in an embodiment of this utility model; Figure 4 This is a schematic diagram of the frame profile structure according to an embodiment of the present utility model; Figure 5 This is a schematic diagram of the base plate structure in an embodiment of the present utility model; Among them, 1. Main frame; 11. Frame profile; 111. Hollow cavity; 112. Reinforcing rib; 12. Corner connector; 2. Base plate structure; 21. Weight reduction hole; 22. Reinforcing plate; 3. Elastic limit block; 4. Pressure rod assembly; 41. Quick release pressure rod; 42. Connecting seat; 43. Eccentric wheel locking structure; 5. Integrated mounting bracket; 51. Oblong hole. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0025] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein in the specification of the application is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification, claims and drawings of this application are intended to cover non-exclusive inclusion.

[0026] The term "embodiment" as used herein means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of the phrase "embodiment" in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0027] Furthermore, the terms "first," "second," etc., in the specification and claims of this application or in the aforementioned drawings are used to distinguish different objects rather than to describe a specific order, and may explicitly or implicitly include one or more of the features.

[0028] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, "connection" or "joining" in mechanical structures can refer to a physical connection, such as a fixed connection, for example, a connection fixed by fasteners, such as a connection fixed by screws, bolts, or other fasteners; a physical connection can also be a detachable connection, such as a snap-fit ​​or interlocking connection; a physical connection can also be an integral connection, such as a connection formed by welding, bonding, or integral molding. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0029] To make the contents of this utility model easier to understand, the present utility model will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0030] like Figure 1-5As shown in Embodiment 1, a lightweight commercial vehicle battery frame bracket assembly is provided. It mainly consists of a main frame 1 made of aluminum alloy profiles, a hollow base plate structure 2 located at the bottom of the main frame 1, an elastic limiting block 3 located inside the main frame 1, a clamping rod assembly 4 movably connected to the top of the main frame 1, and an integrated mounting bracket 5 located outside the main frame 1 for connection to the vehicle frame longitudinal beams. The integrated mounting bracket 5 is welded to the main frame 1 and has an elongated hole 51 for connection to the vehicle frame. The main frame 1 and each component are connected and reinforced using friction stir welding.

[0031] The main frame 1 is specifically composed of four frame profiles 11 and four corner connectors 12 assembled together. The cross-section of the frame profile 11 is a hollow cavity structure 111 with multiple reinforcing ribs 112. The hollow cavity structure achieves the maximum moment of inertia of the cross section with minimal material, thus providing extremely high bending and torsional stiffness. The corner connectors 12 are cast aluminum alloy parts, which are inserted into the frame profiles 11 at both ends and fastened with bolts, and are also welded. The aluminum alloy profiles are made of 6005A or 6061 grade aluminum alloy, and their surfaces are anodized. This significantly reduces weight and improves corrosion resistance while ensuring material strength.

[0032] Specifically, in this embodiment, the base plate structure 2 is a stamped aluminum alloy plate. The base plate structure 2 has multiple weight-reducing holes 21 and multiple upward-protruding reinforcing plates 22, with the reinforcing plates 22 having a wavy shape. In this way, the weight-reducing holes 21 directly remove unnecessary material, while the reinforcing plates 22 compensate for any stiffness loss that may be caused by the holes, achieving a balance between lightweight and stiffness.

[0033] To securely clamp the battery, the clamping rod assembly 4 in this embodiment specifically includes a quick-release clamping rod 41, an eccentric wheel locking structure 43, and connecting seats 42 fixed to both sides of the main frame 1. One end of the quick-release clamping rod 41 and the eccentric wheel locking structure 43 are respectively hinged to the connecting seats 42 on both sides. The quick-release clamping rod 41 and the eccentric wheel locking structure 43 can lock and clamp together to clamp the battery.

[0034] refer to Figure 1-5 As shown in Embodiment 2, a lightweight commercial vehicle battery frame bracket assembly is provided, the core of which is a main frame 1 made of high-strength aluminum alloy profiles such as 6005A. The main frame 1 is formed by bolting together four side frame profiles 11 and four cast aluminum alloy corner connectors 12 to form a sturdy rectangular frame.

[0035] The cross-sectional design of the frame profile 11 is crucial. It is a hollow cavity structure 111, internally divided and reinforced by multiple reinforcing ribs 112. This design makes the profile highly efficient in bearing bending and torsional moments, achieving maximum stiffness with minimal material.

[0036] At the bottom of the main frame 1, a stamped aluminum alloy base plate structure 2 is fixed. Multiple weight-reducing holes 21 are regularly distributed on the base plate 2; these holes remove material that does not affect the main load-bearing function. Simultaneously, upward-protruding corrugated reinforcing plates 22 are stamped on the base plate 2; these reinforcing plates 22 effectively improve the local stiffness and deformation resistance of the base plate.

[0037] At the four inner corners of the main frame 1, elastic rubber limiting blocks 3 are glued. These are used to provide flexible support and cushioning from the side after the battery is inserted, preventing the battery from rigidly colliding with the metal frame due to vehicle vibration.

[0038] Two connecting seats 42 are fixed on both sides of the top of the main frame 1. Each connecting seat 42 is hinged with a quick-release pressure bar 41 and an eccentric wheel locking structure 43, which can quickly lock or release the battery. After the battery is placed in the frame, pressing down the quick-release pressure bar 41 and locking it will firmly press the battery down from above and prevent it from jumping.

[0039] Integrated mounting brackets 5 are integrally welded to both sides of the outer side of the main frame 1. Each integrated mounting bracket 5 has an elongated hole 51 for securing the entire bracket assembly to the longitudinal beams of the frame via bolts. The design of the elongated hole 51 allows for fine-tuning during installation to accommodate manufacturing tolerances on the frame.

[0040] The assembly process in this embodiment is as follows: First, the four frame profiles 11 and the four corner connectors 12 are assembled into the main frame 1 using bolts. Then, the base plate 2 with reinforcing plate 22 and weight-reducing holes 21 is welded to the bottom of the main frame 1. Next, the elastic limiting block 3 is glued to the inside, and the connecting seat 42 and the integrated mounting bracket 5 are welded to the designated positions. Finally, the quick-release pressure rod 41 and the eccentric wheel locking structure 43 are assembled. After the entire assembly undergoes anodizing surface treatment, it is ready for use.

[0041] In the description of this specification, references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0042] The above specific embodiments further illustrate the technical problems, technical solutions, and beneficial effects of this utility model. It should be understood that the above descriptions are merely specific embodiments of this utility model and are not intended to limit this utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A lightweight commercial vehicle battery frame bracket assembly, characterized in that: The main frame (1) is made of aluminum alloy profiles, a hollow base plate structure (2) is set at the bottom of the main frame (1), an elastic limiting block (3) is set inside the main frame (1), a clamping rod assembly (4) is movably connected to the top of the main frame (1), and an integrated mounting bracket (5) is set outside the main frame (1) and used to connect with the longitudinal beam of the vehicle frame. The main frame (1) includes four side profiles (11) and four corner connectors (12) that are assembled with each other. The cross-section of the frame profile (11) is a hollow cavity (111) structure with multiple reinforcing ribs (112).

2. The lightweight commercial vehicle battery frame bracket assembly according to claim 1, characterized in that: The base plate structure (2) is a stamped aluminum alloy plate.

3. The lightweight commercial vehicle battery frame bracket assembly according to claim 2, characterized in that: The base plate structure (2) has multiple weight-reducing holes (21) and multiple upward-protruding reinforcing plates (22).

4. A lightweight commercial vehicle battery frame bracket assembly according to claim 3, characterized in that: The reinforcing plate (22) is wavy.

5. A lightweight commercial vehicle battery frame bracket assembly according to claim 1, characterized in that: The clamping rod assembly (4) includes a quick-release clamping rod (41), an eccentric wheel locking structure (43), and a connecting seat (42) fixed to both sides of the main frame (1). One end of the quick-release pressure rod (41) and the eccentric wheel locking structure (43) are respectively hinged to the connecting seats (42) on both sides. The quick-release pressure rod (41) and the eccentric wheel locking structure (43) can lock and clamp together to press the battery.

6. A lightweight commercial vehicle battery frame bracket assembly according to claim 1, characterized in that: The integrated mounting bracket (5) and the main frame (1) are integrally formed or welded together.

7. A lightweight commercial vehicle battery frame bracket assembly according to claim 6, characterized in that: The integrated mounting bracket (5) has an elongated hole (51) for connecting to the vehicle frame.

8. A lightweight commercial vehicle battery frame bracket assembly according to claim 1, characterized in that: The corner connector (12) is a cast aluminum alloy part.

9. A lightweight commercial vehicle battery frame bracket assembly according to claim 1, characterized in that: The aluminum alloy profile is made of 6005A or 6061 grade aluminum alloy, and its surface has undergone anodizing treatment.

10. A lightweight commercial vehicle battery frame bracket assembly according to claim 1, characterized in that: The components of the main frame (1) are connected by friction stir welding.

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