How to install batteries in electric trucks

Abstract

To provide a technique for loading a cell on an electric truck in which the cell-loading capacity can be freely set by placing a cell in a space between a main sill and a cross sill located between a location below a load-carrying platform and a chassis frame and that is strong against a sideways damage.SOLUTION: In an electric truck, the problem is where a cell is to be loaded. One method for loading the cell on the outer side of a chassis frame or a method for loading the cell between chassis frames has been provided and practiced. The former method is weak against a sideways damage and thus the measures need to be taken, and in the latter method, since a variety of devices are present in the chassis frames, the cell capacity of the cell that can be loaded is limited. Therefore, basically, by utilizing sills formed between a load-carrying platform and the chassis frame, the cell is loaded in a space between the sills. The shape of the sill is contrived and thus the design flexibility of the cell-loading capacity can be attained.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a so-called truck of the type that loads cargo on a loading platform behind the driver's seat, and to a battery mounting method for a battery-powered electric truck. [Background technology]

[0002] EV vehicles powered by secondary batteries are attracting attention as a clean form of transportation that does not emit carbon dioxide (CO2). The first reason is that, unlike vehicles that run on internal combustion engines, they run by driving a motor with electricity stored in secondary batteries, so they do not emit CO2 and are quiet and have a comfortable ride. The second reason is that maintenance costs, including fuel costs, are cheaper than vehicles with diesel engines, etc., so there are thought to be great advantages to introducing them.

[0003] However, current electric trucks have the disadvantage of limiting the amount of cargo they can carry because they use part of the loading compartment to accommodate the batteries. To solve this problem, a method has been proposed in which the batteries are mounted between the tires (Patent No. 4039207). However, this method limits the amount of battery capacity because the batteries must fit into the available space on the side of the truck, which ultimately affects the truck's mileage. Furthermore, because the batteries are mounted on the side of the truck, there are safety concerns in the event of a truck accident, and countermeasures are needed to address this.

[0004] One solution proposed is to mount the battery between sturdy metal structures called chassis frames, which are constructed beneath the truck bed (see, for example, JP 2021-8221). This method does indeed improve safety by housing the battery between sturdy chassis frames, making it resistant to side damage. However, various devices are typically mounted between the chassis frames, and in so-called hybrid vehicles powered by both an engine and a battery, a propeller shaft is located between the engine, which is installed at the front, and the differential device that drives the rear wheels, which can impose many limitations on mounting the battery.

[0005] Generally, truck manufacturing involves two parts: a truck manufacturer, which produces the truck itself, and a truck body builder, which designs and manufactures the bed area where cargo is carried according to customer requirements. Truck manufacturers manufacture the driver's seat area, including the drivetrain, and the rear wheel assembly, which consists of two sturdy metal frames called the chassis frame on which the bed is mounted. Truck body builders then build the necessary cargo compartment or side panels to hold the cargo in the bed according to customer requirements. To achieve this, they manufacture a foundation consisting of horizontal and vertical joists between the chassis frame and the cargo compartment.

[0006] The present invention relates to a method of mounting batteries using these horizontal and vertical joists, and provides a battery mounting method for an electric truck that allows the amount of batteries to be mounted to be freely changed by configuring the joists in various shapes, and is also resistant to damage from the side. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Patent No. 4039207: Battery device for electric vehicles [Patent Document 2] Patent Publication 2021-8221 Electric Truck Summary of the Invention [Problem to be solved by the invention]

[0008] The problem to be solved by this invention is related to the method of mounting batteries on electric trucks. Mounting batteries in the space under the truck bed, avoiding the tires and other devices, limits the amount of batteries that can be mounted due to the limited space, and also poses safety issues regarding side damage. Mounting batteries between sturdy metal chassis frames provides protection against side damage, but the presence of various devices and propeller shafts within the chassis frame limits the amount of batteries that can be mounted. [Means for solving the problem]

[0009] In consideration of these problems, this proposal provides a battery mounting method for electric trucks that is resistant to lateral damage and allows for flexible design of the battery capacity by mounting the batteries between the floor joists constructed between the loading platform and the chassis frame. The method is explained below with reference to the drawings.

[0010] Figure 1 shows a simplified diagram of a truck, with Figure 1(A) showing a side view and Figure 1(B) showing a top view. When a truck bodybuilder takes over a vehicle from a truck manufacturer, with the driver's seat vehicle and the chassis frame portion of the vehicle connected, they build a structure using sturdy metal materials called vertical and horizontal joists on top of the chassis frame to support the loading platform, as shown in the figure. The vertical joists are generally fixed on top of the chassis frame, and the horizontal joists are placed on top of them at a 90-degree angle. Note that this example shows a typical vertical and horizontal joist structure, but it is not limited to this, and the configuration can be changed to suit various battery shapes and other conditions.

[0011] Figure 2 is a schematic diagram of the rear loading platform of an electric truck from the driver's seat. Figure 2(A) shows the most basic battery installation method. 1 shows a front-to-rear view of the truck, and 2 shows a side view. 3 shows the rear tires, and 4 shows a sturdy metal chassis frame attached to the rear of the vehicle where the driver sits. 5 is a framework called a joist, which is built between the chassis frame and the floor board (6). 7 varies depending on the customer's request, from a box-shaped loading platform with a roof to a roofless framework only. 8 shows the installed battery. This diagram shows an example in which the joist (5) is high enough to accommodate the battery. One advantage of the battery installation method shown in this diagram is that the battery is installed under the loading platform, which can lower the center of gravity of trucks, even if the center of gravity tends to be high due to the weight of the loading platform.

[0012] Figure 2(B) shows another battery mounting method, with parts that perform the same functions as in Figure 2(A) being designated by the same numbers. In this figure, the battery is taller than the standard joist 5-1, so a second joist 5-2 is stacked on top of 5-1. Note that the upper part of the loading platform 7 is omitted.

[0013] Figure 2(C) shows yet another method of mounting batteries, in which parts that perform the same functions as in Figure 2(A) are designated by the same numbers. In this figure, batteries are also mounted inside the chassis frame 4 to increase battery height.

[0014] Figure 2(D) shows yet another battery mounting method, with parts that perform the same functions as in Figure 2(A) being designated with the same numbers. In this figure, in order to further increase the amount of batteries that can be mounted, in addition to the battery mounting method (8-1) in Figure 2(C), batteries (8-2) are also mounted on the outside of the chassis frame 4 and joists 5. Although not shown in the figure, various battery mounting methods can be considered that combine the methods (A) to (D)4 in Figure 2.

[0015] Figures 3(A) to 3(D) show the chassis frame, joists (horizontal and vertical joists), underframe, floorboards, battery, and other components in more detail. Figures 3(A) and 3(C) show the horizontal joists, vertical joists, underframe, and floorboards viewed from diagonally above, with portions of the floorboards cut away to reveal the joists. In these figures, the vertical joists are arranged parallel to the longitudinal direction of the vehicle, and the horizontal joists are arranged on top of the vertical joists. A frame called the underframe surrounds the horizontal joists. The floorboards are arranged on top of the horizontal joists, and the cargo is placed on top of these. Figure 3(B) is a cross-sectional view of (A) from the front and rear, showing the chassis frame and crossmembers not shown in Figure 3(A). Spacers are present between the chassis frame and the vertical joists. This figure shows the battery installed between the vertical joists. The battery can be removed from the rear of the truck by sliding it out as indicated by the arrow in Figure 3(A).

[0016] Figure 3(D) is a cross-sectional view of Figure 3(C) seen from the side, showing how the battery is installed between the horizontal joists. The battery is installed on a convex jig attached below the horizontal joists. When performing battery maintenance, the battery is removed from the bottom along with the convex jig, as shown in Figure 3(C).

[0017] Figure 4 shows the battery mounting method shown in Figure 2 in more detail. Figure 4(A) shows the battery mounted between the vertical joists. Below the battery is a support plate that supports the battery and prevents water and snow melting agents from entering the battery from below. The support plate also functions as a cooling plate that utilizes airflow. Fins can also be installed below the support plate to increase the cooling effect.

[0018] Figure 4(B) shows an example in which a battery support plate is attached above the battery so that it covers the vertical joists. This support plate not only supports the battery but also serves as a cooling plate for air cooling. Figure 4(C) shows another battery support method. Type A shows a box-shaped support jig attached between the vertical joists and the battery. Type B shows an L-shaped support jig attached between the horizontal joists and the battery.

[0019] Figure 4(D) shows a method for mounting batteries between horizontal joists. In this example, the battery support plate is placed below the battery, but it is also possible to place the support plate above the battery. In this example, the support plate also serves a cooling function. Figure 4(E) combines the battery mounting configurations of Figures 3(A) to 3(D) and shows that by placing the battery in the space between the vertical and horizontal joists, the battery depth increases, making it possible to increase the battery load capacity. The battery support jig has a convex shape, and the top part of the jig is fixed to the horizontal joist with bolts, etc., and the battery is installed on the side of the convex shape. In this case, the floorboard above the battery can be removed to allow for maintenance such as battery replacement.

[0020] Figure 5 shows an example of horizontal and vertical joists arranged in a grid pattern. The battery box in Figure 5(A) consists of a set of six battery modules, placed in the space between the horizontal and vertical joists. The shape and dimensions of one battery module are shown at the bottom of Figure 5(A), using a Toshiba SCiB battery as an example. This figure shows an example with two battery boxes, but if there is sufficient space between the horizontal and vertical joists, more battery boxes can be installed. Also, while air holes are shown in some of the horizontal joists to allow air to cool the batteries, these air holes can be located anywhere on any horizontal or vertical joist, and it is of course possible for all joists to have air holes or for there to be no air holes at all.

[0021] Figure 5(B) shows an example of two battery boxes, each containing 12 batteries as one bank. In this way, one box can contain one bank using 12 battery modules. The diagram below shows one bank, which also contains a BMS (Battery Management System) that has functions such as monitoring the battery status.

[0022] Figure 6 shows an example of a trailer-type truck that, unlike previous battery mounting methods, can also mount batteries in the driver's vehicle. Because it is a trailer type, the trailer section towed by the driver's vehicle is also equipped with rear tires. There is no drive mechanism in the trailer section, but the drive mechanism is installed in the driver's vehicle, so battery 1 is mounted in that section, but this battery has a small capacity as it only needs to have enough battery capacity to run the driver's vehicle. On the other hand, the trailer section (the towed vehicle) carries cargo, so battery 2 with a capacity commensurate with that is mounted. In this way, by mounting batteries in two locations, we propose a battery mounting method that is suited to the driving mode.

[0023] Figure 7 shows yet another method of mounting batteries on an electric truck. In this method, the batteries are mounted in the space between the vehicle on the driver's side and the vehicle on the cargo side. Figure 7(A) is a side view of the truck, and Figure 7(B) is a bird's-eye view of the truck from above. Since bodybuilders design and manufacture the loading compartment by modifying vehicles received from truck manufacturers, it is easy to create a space for mounting the batteries. The figure shows three battery packs stacked vertically. Furthermore, a configuration in which the batteries are mounted between the floor joists, as represented in Figure 3, can also be used. [Industrial Applicability]

[0024] This invention relates to a method of mounting batteries on electric trucks. Conventional battery mounting methods, such as mounting the batteries between the chassis frame, have problems such as limited battery capacity, and mounting the batteries on the outside of the frame to avoid tires, etc., has problems such as vulnerability to lateral damage. However, by installing the batteries in the space between the vertical and horizontal joists that exist under the loading platform and the chassis frame, it is possible to freely set the battery capacity, creating an electric truck that is resistant to lateral damage. This can contribute to the electrification of truck transport, which is responsible for logistics, and is therefore effective in reducing CO2 emissions. [Brief explanation of the drawings]

[0025] [Figure 1] Figure 1(A) shows a side view of the truck, and Figure 1(B) shows a bird's-eye view. [Figure 2] Figures 2(A) and 2(B) show examples of batteries installed in the space between the electric truck bed and the chassis frame. Figure 2(C) shows an example of batteries being installed between the chassis frame, and Figure 2(D) shows an example of batteries being installed on the outside of the chassis frame, increasing the amount of battery capacity. [Figure 3] Figures 3(A) and 3(C) are views of the vertical joists, horizontal joists, and floorboards seen from diagonally above, and Figure 3(B) is a cross-sectional view of Figure 3(A) seen from the front and back, and Figure 3(D) is a cross-sectional view seen from the side. Figures 3(A) and 3(C) show how to remove batteries installed in the space between vertical or horizontal joists from the side or below to facilitate maintenance and replacement of the batteries. [Figure 4] Various methods for mounting batteries in the space between vertical and horizontal joists are shown. Figure 4(A) shows an example of a battery support plate being placed under the battery in the space between vertical joists. Figure 4(B) shows an example of a battery support plate being placed on top of the battery. Figure 4(C) shows Type A, in which the battery is supported from the vertical joists by a box-shaped jig, and Type B, in which the battery is supported from the horizontal joists by an L-shaped jig. Figure 4(D) shows an example of a battery being mounted in the space between horizontal joists with a battery support plate being placed under the battery. Figure 4(E) shows an example of a battery being mounted with a convex support plate being placed under the horizontal joists. [Figure 5] The diagram shows batteries arranged in a space with a grid-like structure of horizontal and vertical joists. Figure 5(A) shows an example of a battery module arrangement in groups of six, while Figure 5(B) shows an example of a battery bank with 12 battery modules and a BMS. [Figure 6] Diagram showing how batteries are installed in trailer-type trucks [Figure 7] This is a diagram showing how the battery is installed between the driver's seat and the cargo compartment of a truck. Figure 7(A) is a side view, and Figure 7(B) is a bird's-eye view from above.

Claims

1. A method of installing a battery in a gap between a structure called a joist that exists between the chassis frame and the bed of a truck, a support plate is disposed below or above the battery, and the support plate functions as a cooling plate utilizing air flow; The joists are composed of horizontal joists and vertical joists, and at least one of the horizontal joists and the vertical joists is provided with an air hole for cooling the battery with air.

2. A battery mounting method for an electric truck according to claim 1, characterized in that, if the height of the floor joist is lower than the height of the battery, a second floor joist is constructed on top of the first floor joist, so that the total height of the two floor joists is equal to or higher than the height of the battery.

3. A battery installation method for an electric truck according to claim 1, characterized in that the batteries installed between the joists are also installed in the empty space of the chassis frame below the joists.

4. A battery mounting method for an electric truck according to claim 1, characterized in that batteries are mounted in the space between the horizontal joists or in the spaces between both the horizontal joists and the vertical joists.

5. The battery mounting method for an electric truck according to claim 1, wherein the battery is fixed to the horizontal joists and / or vertical joists using a jig.

6. A battery mounting method for an electric truck according to claim 1, characterized in that the vertical joists and horizontal joists are configured in a lattice-like structure, and the battery is mounted in a space defined by the vertical joists and horizontal joists.

7. The battery mounting method for an electric truck according to claim 1, characterized in that the mounted batteries are stored in a box as a set of multiple battery modules, and a BMS (Battery Management System) is included, so that the stored battery box has the function of handling a certain predetermined unit (bank) of electric energy.

8. A method for loading batteries onto a truck consisting of a vehicle in which a driver rides and a trailer mainly consisting of a cargo bed towed by the vehicle in which the driver rides, characterized in that batteries are installed in both the vehicle in which the driver rides and the trailer towed by the vehicle, the method for loading batteries onto an electric truck according to claim 1.

9. A battery mounting method for an electric truck as described in claim 1, characterized in that the battery mounted between the horizontal joists can be removed by moving it downward from under the truck together with a convex jig, and a door or jig is provided that allows access to the battery.

10. The method for mounting a battery on an electric truck according to claim 1, wherein the support plate is provided with fins for air cooling.

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