A front-end integrated height-lowering arrangement system for a power battery frame of a pure electric heavy truck
Patent Information
- Application Number
- CN202522105073.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-29
- Publication Date
- 2026-09-18
- Estimated Expiration
- 2035-09-29
AI Technical Summary
[0006]2.质心与通过性恶化：整车高度逼近4000mm(GB1589-2016法规限值4000mm)，质心高度达1.35m；侧倾角降至28°，侧翻风险增加20％
[0017] This utility model removes the battery cooling unit and high/low voltage boxes from the rear battery compartment and places them at the front of the vehicle frame, breaking the industry convention of "rear-mounted functional stacking." The height of the battery top frame is reduced by 25.6% (2320mm → 1725mm), resolving the contradiction of "high capacity and low height being mutually exclusive" (see...). Figure 2 (Hierarchical structure).
Smart Images
Figure CN224766846U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to an integrated height reduction arrangement system for the front end of the power battery frame of a pure electric heavy-duty truck, belonging to the field of new energy heavy-duty trucks. Background Technology
[0002] The "2024 China New Energy Heavy Truck Industry Development Report" clearly states that currently, over 90% of pure electric heavy trucks in the industry adopt a rear-mounted battery layout. In this layout, the battery cooling unit, high / low voltage boxes, and battery pack components are arranged in layers within the upper battery frame system. The cooling unit and high / low voltage boxes require a separate layer, resulting in the upper frame height exceeding the top of the cab when the battery capacity exceeds 400.61 kWh, becoming the highest point of the entire vehicle.
[0003] Taking a 422.87kWh rechargeable power battery upper frame system from a mainstream battery manufacturer as an example: the bottom layer is the cooling unit and high and low voltage boxes, and the remaining 6 layers are battery packs, with a single layer height of 345mm; the total height is 2320mm.
[0004] This solution has four major flaws:
[0005] 1. Increased wind resistance: The top of the upper frame is 380mm higher than the cab, which disrupts the aerodynamic shape of the vehicle, increases the drag coefficient by 0.03, and reduces the driving range by 8.5%.
[0006] 2. Deterioration of center of gravity and passability: The overall vehicle height approaches 4000mm (GB1589-2016 regulation limit of 4000mm), and the center of gravity height reaches 1.35m; the roll angle drops to 28°, increasing the risk of rollover by 20%.
[0007] 3. Poor thermal management efficiency: The rear-mounted cooling unit is located in the tail section of the vehicle, with a heat dissipation efficiency of only 45%; the frequency of high temperature alarms increases by 100-200%.
[0008] 4. Low maintenance efficiency: Maintenance of the high-level battery compartment requires specialized equipment such as a lifting platform, and a single maintenance takes 3.2 hours, which is about 1.7 hours longer than the maintenance time specified in Appendix B of "GB / T 32960-2023 Electric Vehicle Remote Service and Management Specification". Utility Model Content
[0009] The purpose of this invention is to design a height reduction scheme for a rear-mounted power battery upper frame system. This involves removing the battery cooling unit, high-voltage box, and low-voltage box from the power battery upper frame system and relocating them to the front of the vehicle frame. All components located at the front of the frame are arranged in four layers, improving the space utilization at the front of the frame. Without altering the overall vehicle drive architecture or the structure of the cab components, the overall vehicle height is reduced by decreasing the number of layers in the power battery upper frame. This achieves the goals of reducing the vehicle's frontal area, lowering the chassis center of gravity, and improving the vehicle's range, handling stability, driving safety, and passability.
[0010] This utility model is achieved through the following technical solution:
[0011] A height-reducing arrangement system for the front end of the power battery frame of a pure electric heavy-duty truck, which establishes a vertical four-layer gradient arrangement system at the front end of the frame:
[0012] The first layer includes a multi-function unit 2-1 and a high-voltage battery box 2-2, located in the center of the combined frame; the distance from the vehicle frame plane is ≤200mm. The output end of the high-voltage battery box is installed horizontally side by side with the multi-function unit. Three rubber shock-absorbing pads distributed in an equilateral triangle are installed between the bottom of the high-voltage battery box and the bottom of the multi-function unit and the combined frame. A rubber damper is set at the apex of the combined frame to reduce the acceleration of vehicle vibration, meeting ISO standards.
[0013] The second layer includes an air filter 2-9, a VCU 2-3, an air conditioning compressor 2-4, and a low-pressure battery box 2-8, located on the right side of the combined frame, and also includes a steering pump 3-1, located on the left side of the combined frame;
[0014] The three layers include a battery cooling unit 2-7 and a motor controller 2-5, located in the center of the combined frame; the battery cooling unit 2-7 and the motor controller 2-5 share a heat dissipation duct;
[0015] The four layers include an air compressor 2-6, located in the center of the combined frame. The bottom of the compressor is 50mm higher than the front anti-drill bumper (meeting the approach angle requirements of GB26511-2011), and collision protection is provided by the bumper assembly 1-1.
[0016] The rubber damper has a Shore hardness of 70±5.
[0017] This utility model removes the battery cooling unit and high / low voltage boxes from the rear battery compartment and places them at the front of the vehicle frame, breaking the industry convention of "rear-mounted functional stacking." The height of the battery top frame is reduced by 25.6% (2320mm → 1725mm), resolving the contradiction of "high capacity and low height being mutually exclusive" (see...). Figure 2 (Hierarchical structure). Attached Figure Description
[0018] Figure 1Schematic diagram of layered layout;
[0019] Figure 2 Layered layout schematic diagram (right view);
[0020] Figure 3 Layered layout schematic diagram (left rear view). Detailed Implementation
[0021] like Figure 1-3 As shown, this utility model is an integrated height-reducing arrangement system for the front end of a pure electric heavy-duty truck power battery frame. It establishes a vertical four-layer gradient arrangement system at the front end of the frame. The four-layer integrated arrangement of the front-end frame components is as follows: the first layer mainly consists of a multi-function unit and a high-voltage battery box; the second layer consists of a VCU, an air filter intake device, and an air conditioning compressor; the third layer consists of a battery cooling unit and a motor controller; and the fourth layer consists of an air compressor. The bottom 1-3 of the fourth-layer air compressor is higher than the front anti-drill bumper 1-250mm, without affecting the vehicle's approach angle, and is physically protected by the existing bumper assembly 1-1. Figure 1 This is a schematic diagram of the layered layout.
[0022] Figure 2 , 3 This is a schematic diagram of the layered layout. The first layer includes: a multi-function controller 2-1 and a high-voltage battery box 2-2, located in the center of the combined frame; ≤200mm from the vehicle frame plane, installed horizontally side-by-side. The output end of the high-voltage battery box is directly connected to the multi-function controller, reducing wiring harness length by 40%. The high-voltage battery box and the multi-function controller adopt a "three-point floating installation," meaning that three rubber shock-absorbing pads arranged in an equilateral triangle are installed between the bottom of the high-voltage battery box and the bottom of the multi-function controller and the combined frame; a rubber damper is installed at the apex of the combined frame to reduce vehicle vibration acceleration, meeting ISO standards.
[0023] The second layer includes: air filter 2-9, VCU 2-3, air conditioning compressor 2-4, and low-pressure battery box 2-8, located on the right side of the combined frame; and includes steering pump 3-1, located on the left side of the combined frame, saving 30% of lateral space.
[0024] The three layers include: battery cooling unit 2-7 and motor controller 2-5, located in the center of the combined frame; battery cooling unit 2-7 and motor controller 2-5 share a heat dissipation air duct, and the heat dissipation efficiency is improved by 20% compared with the rear-mounted type.
[0025] The four layers include: air compressors 2-6, located in the center of the combined frame; the bottom of the compressor is 1-2 to 50mm higher than the front anti-drill bumper. Figure 1 Serial numbers 1-2 (compliant with GB26511-2011 approach angle requirements) are protected by bumper assembly 1-1.
[0026] The four-layer integrated layout at the front of the chassis completely solves the industry bottleneck of the incompatibility between high battery capacity (>400kWh) and low height (<4000mm) in pure electric heavy-duty trucks. Taking a model with a capacity of 422.87kWh as an example, the results are as follows:
[0027] Table 1: Calculation Results of a 422.87kWh Pure Electric Heavy Truck
[0028] 1 Battery top frame height 2320mm 1725mm -25.6％ 2 drag coefficient 0.78 0.72 -7.7％ 3 Center of mass height 1.35m 1.18m -12.6％ 4 Range (full range) 320km 350km +9.4％
[0029] This utility model has the following beneficial effects:
[0030] 1. Four-layer gradient space compression technology
[0031] A vertical four-layer gradient layout system is established at the front of the chassis, improving space utilization by 30%. Among them, the air compressor at the bottom layer (4 layers) is 50mm higher than the bumper (compliant with GB26511);
[0032] 2. Improved heat dissipation efficiency
[0033] The battery compartment cooling unit shares an air duct with the motor controller. Simulation calculations show that the heat dissipation efficiency is 20% higher than that of the battery compartment rear-mounted solution.
[0034] 3. Vibration Suppression: The high / low voltage boxes and cooling units of the battery compartment are integrated and fixed to the combined frame at the front of the vehicle frame. The fixing method adopts a three-point suspension system + damper (Shore hardness 70±5), reducing the vibration acceleration to 5.3m / s². 2 (ISO16750-3 verified).
Claims
1. A front-end integrated height-reducing arrangement system for the power battery frame of a pure electric heavy-duty truck, characterized in that: A vertical four-layer gradient arrangement system is established at the front end of the chassis: The first layer includes a multi-function unit and a high-voltage battery box, located in the center of the combined frame; the distance from the vehicle frame plane is ≤200mm. The output end of the high-voltage battery box is installed horizontally side by side with the multi-function unit. Three rubber shock-absorbing pads distributed in an equilateral triangle are installed between the bottom of the high-voltage battery box and the bottom of the multi-function unit and the combined frame. A rubber damper is set at the apex of the combined frame to reduce the acceleration of vehicle vibration, meeting ISO standards. The second layer includes an air filter, VCU, air conditioning compressor, and low-pressure battery box, located on the right side of the combined frame, and also includes a steering pump, located on the left side of the combined frame. The three layers include a battery cooling unit and a motor controller, located in the center of the combined frame; the battery cooling unit and the motor controller share a heat dissipation duct; The four layers include an air compressor located in the center of the combined frame. The bottom of the compressor is higher than the front anti-drill bumper, which meets the approach angle requirements of GB26511. Collision protection is provided by the bumper assembly.
2. The integrated height-reducing arrangement system for the front end of the power battery frame of a pure electric heavy-duty truck according to claim 1, characterized in that: The output terminal of the battery high-voltage box is directly connected to the multi-function connector in a horizontal parallel manner via a copper busbar.
3. The integrated height-reducing arrangement system for the front end of the power battery frame of a pure electric heavy-duty truck according to claim 1, characterized in that: The bottom of the compressor is 50mm higher than the front anti-drill bumper.
4. The integrated height-reducing arrangement system for the front end of the power battery frame of a pure electric heavy-duty truck according to claim 1, characterized in that: The rubber damper has a Shore hardness of ±.