Design method for traction battery pack for electric heavy truck, and traction battery pack

Abstract

Disclosed in the present application are a design method for a traction battery pack for an electric heavy truck, and a traction battery pack. The traction battery pack is designed on the basis of whole-vehicle parameters of the electric heavy truck, so that an obtained target traction battery pack model can meet vehicle requirements, and the traction battery pack is highly integrated with the electric heavy truck; and in a design process, deformation-prone weak areas and stress-suitable assembly points of the traction battery pack are determined on the basis of a stress simulation result for the traction battery pack model, reinforcing members are configured for the weak areas to prevent the structural deformation of the traction battery pack, and auxiliary members are configured for the assembly points to facilitate the installation of the traction battery pack on a frame chassis. Compared with the solution of using a standard-sized traction battery pack in the prior art, the solution of the present application can reduce the size of the traction battery pack and utilize the space of the frame chassis to the greatest extent, thereby improving the degree of integration of the whole vehicle.

Description

A design method for a power battery pack for an electric heavy truck and a power battery pack

[0001] This application claims priority to the Chinese patent application filed with the Patent Office of China on December 1, 2023, with application number 202311636421.9 and invention name “A method for designing a power battery pack and a power battery pack for electric heavy-duty trucks”, the entire contents of which are incorporated by reference into this application. Technical Field

[0002] The present application relates to the field of power battery technology, and in particular to a design method for a power battery pack for an electric heavy truck and a power battery pack. Background Art

[0003] The lightweight requirements for electric heavy-duty trucks are gradually increasing. The volume and weight of the power battery pack play an important role in the lightweight design of the entire vehicle, and are of great significance for reducing the weight of the entire vehicle and improving the space utilization of the entire vehicle.

[0004] Currently, due to the low volume of units produced, electric heavy-duty trucks typically purchase power battery packs and install them on the vehicle. During installation, a frame for the battery pack is first assembled in the reserved space on the vehicle. The power battery pack is then placed within the frame and the circuit connections are completed. However, purchased power battery packs are designed by the battery manufacturer according to certain standards, with fixed dimensions and weights. The frame space used to install the battery pack is also fixed, making it difficult to maximize the frame space during battery pack placement. Furthermore, the battery frame itself occupies a large area, wasting space on the vehicle.

[0005] Therefore, there is still room for improvement in the design and assembly of power battery packs for electric heavy trucks.

[0006] Summary of the Invention

[0007] The technical problem to be solved by this application is that when the existing power battery pack for electric heavy trucks is installed using a standard battery pack and frame, it causes a large waste of space in the entire vehicle. To this end, this application proposes a power battery pack design method and a power battery pack for electric heavy trucks.

[0008] In response to the above technical problems, this application provides the following technical solutions:

[0009] In a first aspect, the technical solution of the present application provides a method for designing a power battery pack for an electric heavy truck, comprising:

[0010] Obtaining vehicle parameters of the electric heavy truck, including weight information, operating condition information, and frame and chassis space information;

[0011] Determine the cell module selection of the power battery pack according to the weight information and the operating condition information, and determine the target size of the power battery pack according to the frame chassis space information;

[0012] Generate an initial battery pack model based on the battery cell module selection, the target size, and preset functional parts; the preset functional parts include cooling functional parts, sealing functional parts, bearing parts, and connecting parts;

[0013] Simulating a state where the initial battery pack model is assembled to a vehicle frame chassis to obtain a force simulation result of the initial battery pack model;

[0014] Determining assembly point information of the initial battery pack model and the vehicle frame chassis and weak area information of the initial battery pack model according to the force simulation results;

[0015] The initial battery pack model is adjusted, assembly auxiliary parts are configured at assembly points, and reinforcement parts are configured in weak areas to obtain a target battery pack model.

[0016] In some embodiments of the electric heavy-duty truck power battery pack design method, determining the target size of the power battery pack based on the frame chassis space information includes:

[0017] Dividing the frame chassis into a first assembly area, a second assembly area, and a third assembly area according to the frame chassis space information, wherein the second assembly area is an area between two longitudinal beams, and the first assembly area and the third assembly area are symmetrically distributed on the left and right sides of the second assembly area;

[0018] Determining the number of power battery packs in the first assembly area, the second assembly area, and the third assembly area;

[0019] The target size is determined according to the spatial information of the first assembly area, the second assembly area, and the third assembly area and the number of power battery packs.

[0020] In some embodiments of the method for designing a power battery pack for an electric heavy truck, if there are multiple power battery packs in the first assembly area, the second assembly area, and the third assembly area, the method further includes:

[0021] Determining an arrangement of the plurality of power battery packs in the first assembly area, the second assembly area, and the third assembly area;

[0022] The battery pack reinforcement is determined according to the arrangement and the design information of the target battery pack model, wherein the design information includes the target weight of the target battery pack; the battery pack reinforcement includes a reinforcement structure for connecting different power battery packs in the same assembly area into a whole and a reinforcement structure for connecting different power battery packs in different assembly areas into a whole.

[0023] In a second aspect, the technical solution of the present application provides a computer program product, in which program instructions are stored. After a computer or processor reads the program instructions, it executes the power battery pack design method for an electric heavy truck as described in any one of the first aspects.

[0024] In a third aspect, the technical solution of the present application provides a power battery pack obtained by the design method of a power battery pack for an electric heavy truck according to any one of the solutions of the first aspect, comprising a battery pack housing and a battery cell module disposed within the battery pack housing; the battery pack housing comprises a support frame, a bottom plate, a box member that seals gaps in the support frame, and an upper cover; wherein:

[0025] The support frame is a rectangular parallelepiped frame, and each corner of the rectangular parallelepiped frame serves as a weak area; each of the weak areas is equipped with a first reinforcement member that matches the shape of the corner;

[0026] The first reinforcement comprises: a first angle plate provided at an edge corner of the upper surface of the rectangular parallelepiped frame, a second angle plate provided at an edge corner of the lower surface of the rectangular parallelepiped frame, and a first connecting plate connecting the first angle plate and the second angle plate.

[0027] In some embodiments of the power battery pack, the interior space of the rectangular parallelepiped frame is divided into at least two accommodating compartments, and a support frame is provided between two adjacent accommodating compartments.

[0028] A second reinforcement member is provided at a position on the inner wall of the rectangular parallelepiped frame opposite to the support frame; the second reinforcement member includes: a first T-shaped plate provided on the upper side frame of the rectangular parallelepiped frame, a second T-shaped plate provided on the lower side frame of the rectangular parallelepiped frame, and a second connecting plate connecting the first T-shaped plate and the second T-shaped plate;

[0029] Screw holes are provided at corresponding positions of the support frame and the second connecting plate, and the support frame and the second connecting plate are fixedly connected after positioning bolts pass through the screw holes of the support frame and the second connecting plate in sequence.

[0030] In some embodiments of the power battery pack, the edges of the first connecting plate and the second connecting plate are formed with limiting portions, and the limiting portions are used to limit the box component.

[0031] In some embodiments of the power battery pack, a ridge is formed on the second connecting plate, the screw hole on the second connecting plate is formed on the ridge, and a plurality of slots are formed on the ridge.

[0032] In the power battery pack described in some solutions, double-channel seals are provided at the position where the base plate is connected to the support frame, the position where the upper cover is connected to the support frame, and the position where the box component is connected to the support frame.

[0033] In a fourth aspect, the technical solution of the present application provides a battery pack assembly comprising a plurality of power battery packs as described in any one of the second aspects.

[0034] In some embodiments, the battery pack assembly is divided into three groups, one group of power battery packs is arranged between the two longitudinal beams of the frame chassis, and the other two groups of power battery packs are symmetrically arranged on the left and right sides of the frame chassis; each group of power battery packs is fixedly connected to the longitudinal beam.

[0035] The battery pack assembly described in some solutions further includes:

[0036] A third reinforcement member is used to connect different power battery packs in the same assembly area;

[0037] Among them, different power battery packs in the same assembly area are stacked, and the third reinforcement is arranged between two layers of power battery packs. The third reinforcement is fixedly connected to the lower surface of the upper power battery pack and the upper surface of the lower power battery pack through fixing members.

[0038] The battery pack assembly described in some solutions further includes:

[0039] A first auxiliary component is used to connect different power battery packs in different assembly areas;

[0040] Specifically, different power battery packs in different assembly areas are arranged side by side and separated by a longitudinal beam. The first auxiliary component connects the two power battery packs arranged side by side while fixing at least one power battery pack to the longitudinal beam.

[0041] In some embodiments of the battery pack assembly, the first auxiliary parts are provided at both ends of the power battery pack, and each of the first auxiliary parts includes a bending part and a clamping part;

[0042] The clamp is fixedly connected to a power battery pack;

[0043] The bending part includes a first bending portion and a second bending portion that are integrally formed; the first bending portion is fixed to another power battery pack and fixedly connected to the longitudinal beam; the second bending portion extends to the bottom of the clamp and is fixedly connected to the bottom of the clamp.

[0044] In the battery pack assembly described in some solutions, the first bent portion is integrally formed with the supporting skeleton frame of the connected power battery pack.

[0045] The battery pack assembly described in some solutions further includes:

[0046] The second auxiliary component is arranged outside the power battery pack and fixedly connected to the longitudinal beam, and the second auxiliary component is arranged opposite to the second reinforcement component.

[0047] The technical solution of this application has the following technical effects compared with the existing technology:

[0048] The power battery pack design method and power battery pack for electric heavy trucks provided in this application determine the cell module selection and target size in the power battery pack according to the vehicle parameters of the electric heavy truck, so that the designed power battery pack can meet the power supply needs of the electric heavy truck, and the power battery pack can maximize the reasonable use of the frame chassis space during assembly. The initial battery pack model obtained by considering the cell module selection and the preset functional parts can meet the power supply, cooling, sealing and load-bearing functions. At this time, the weight of the initial battery pack model can be estimated. According to the target size and weight of the initial battery pack model, after simulating its state of being assembled to the frame chassis, the force simulation results of the initial battery pack model can be obtained. Under the guidance of the force simulation results, the weak area information of the initial battery pack model can be determined. The weak area information corresponds to the position that is easily deformed. Reinforcements are set in the weak area to prevent the power battery pack structure from deforming. At the same time, in order to ensure that the power battery pack has reasonable and uniform force when installed on the longitudinal beam, the assembly point position of the power battery pack and the longitudinal beam is determined through the force simulation results, and assembly auxiliary parts are set at the assembly point position accordingly to install the power battery pack on the crossbeam.

[0049] The solution provided in this application designs the power battery pack based on the overall vehicle parameters of an electric heavy-duty truck. The resulting target power battery pack model meets vehicle requirements and achieves a high degree of integration between the power battery pack and the electric heavy-duty truck. During the design process, the force simulation results of the power battery pack model are used to identify vulnerable areas of the power battery pack prone to deformation and suitable assembly points for force bearing. Reinforcements are then placed in these vulnerable areas to prevent structural deformation of the power battery pack, and auxiliary components are placed at the assembly points to facilitate installation of the power battery pack on the vehicle chassis. Compared to existing solutions using standard-sized power battery packs, the solution in this application can reduce the volume of the power battery pack and maximize the use of the frame chassis space, thereby improving the overall vehicle integration. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] The preferred embodiments of the present application will be described in detail below with reference to the accompanying drawings, which will help to understand the objects and advantages of the present application.

[0051] FIG1 is a flow chart of a method for designing a power battery pack for an electric heavy truck according to one embodiment of the present application;

[0052] FIG2 is a schematic structural diagram of a support frame according to an embodiment of the present application;

[0053] FIG3 is a schematic diagram of the upper cover structure of a power battery pack according to an embodiment of the present application;

[0054] FIG4 is a schematic diagram of the bottom plate structure of a power battery pack according to an embodiment of the present application;

[0055] FIG5 is a schematic structural diagram of a double-layer power battery pack housing according to an embodiment of the present application;

[0056] FIG6 is a schematic diagram of the assembly structure of the support frame and longitudinal beams of the power battery pack in a scenario where three power battery packs are arranged on the vehicle frame chassis according to one embodiment of the present application;

[0057] FIG7 is a schematic diagram of the structure shown in FIG6 from a rear perspective;

[0058] FIG8 is a schematic diagram of the structure shown in FIG6 from a left perspective;

[0059] FIG9 is a schematic diagram of the structure shown in FIG6 after the upper cover is assembled, viewed from a top view. DETAILED DESCRIPTION

[0060] The following will clearly and completely describe the technical solution of this application in conjunction with the accompanying drawings. Obviously, the embodiments described are only part of the embodiments of this application, not all of them. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of protection of this application.

[0061] In the description of this application, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate the description of this application and simplify the description. They do not indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0062] In the description of this application, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to direct connections, indirect connections through an intermediate medium, or internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in this application based on the specific circumstances.

[0063] In addition, the technical features involved in the different embodiments of the present application described below can be combined with each other as long as they do not conflict with each other.

[0064] The present application provides a method for designing a power battery pack for an electric heavy truck, which is applied to a computer system equipped with simulation software (such as CAE analysis software, FEA simulation software, etc.). As shown in FIG1 , the method includes the following steps:

[0065] S10: Obtaining vehicle parameters of the electric heavy truck, wherein the vehicle parameters include weight information, operating condition information, and frame and chassis space information.

[0066] The entire vehicle parameters of the electric heavy truck are determined when the vehicle is designed, and therefore can be directly obtained.

[0067] S20: Determine the cell module selection of the power battery pack according to the weight information and the operating condition information, and determine the target size of the power battery pack according to the frame chassis space information.

[0068] Weight information and operating condition information can determine the maximum power range required by the vehicle during operation, thereby determining the required battery cell module selection. In order to make the volume of the power battery pack maximize the use of the space in the frame and chassis, the target size of the power battery pack can be determined based on a certain amount of redundancy reserved in the frame and chassis space.

[0069] S30: generating an initial battery pack model according to the cell module selection, the target size and preset functional parts; the preset functional parts include cooling functional parts, sealing functional parts, bearing parts and connecting parts.

[0070] The preset functional components are all placed inside the power battery pack. Compared with the existing method of arranging the above functional components outside, the wiring harness, pipelines, etc. can be concentrated inside the power battery pack, thereby improving the protection of the above functional components and lines.

[0071] S40: Simulate the state in which the initial battery pack model is assembled to the vehicle frame chassis, and obtain a force simulation result of the initial battery pack model.

[0072] The assembly relationship of the initial battery pack model integrating all functions is simulated using CAE analysis software. During the simulation process, the stress simulation results are observed to determine the conditions that should be met under stable and uniform stress conditions.

[0073] S50: Determine assembly point information of the initial battery pack model and the vehicle frame chassis and weak area information of the initial battery pack model according to the force simulation result.

[0074] The purpose of setting the assembly points is to meet the requirement of uniform force on the power battery pack after assembly and to identify weak areas so that reinforcements can be configured for the weak areas to prevent them from deformation.

[0075] S60: Adjust the initial battery pack model, configure assembly aids at assembly points, and configure reinforcements at weak areas to obtain a target battery pack model. The design result of the target battery pack model can meet the requirements of high vehicle integration and space utilization.

[0076] The solution provided in this embodiment determines the cell module selection and target dimensions for the power battery pack based on the overall vehicle parameters of the electric heavy-duty truck, thereby ensuring that the designed power battery pack meets the power supply requirements of the electric heavy-duty truck and maximizes the rational utilization of the vehicle chassis space during assembly. The initial battery pack model, derived by considering the cell module selection and pre-set functional components, meets the power supply, cooling, sealing, and load-bearing requirements. The weight of the initial battery pack model can be estimated. Based on the target dimensions and weight of the initial battery pack model, the initial battery pack model is simulated when assembled to the vehicle chassis. Force simulation results of the initial battery pack model are obtained. Based on these force simulation results, weak areas of the initial battery pack model are identified. These weak areas correspond to locations prone to deformation, and reinforcements are then installed in these weak areas to prevent structural deformation of the power battery pack. Furthermore, to ensure reasonable and uniform stress distribution when the power battery pack is installed on the longitudinal beam, the force simulation results determine the locations of the assembly points between the power battery pack and the longitudinal beam. Assembly aids are then installed at these locations, and the power battery pack is then mounted on the crossbeam.

[0077] The solution provided in this application designs the power battery pack based on the overall vehicle parameters of an electric heavy-duty truck. The resulting target power battery pack model meets vehicle requirements and achieves a high degree of integration between the power battery pack and the electric heavy-duty truck. During the design process, the force simulation results of the power battery pack model are used to identify vulnerable areas of the power battery pack prone to deformation and suitable assembly points for force bearing. Reinforcements are then placed in these vulnerable areas to prevent structural deformation of the power battery pack, and auxiliary components are placed at the assembly points to facilitate installation of the power battery pack on the vehicle chassis. Compared to existing solutions using standard-sized power battery packs, the solution in this application can reduce the volume of the power battery pack and maximize the use of the frame chassis space, thereby improving the overall vehicle integration.

[0078] In some embodiments, in step S20, determining the target size of the power battery pack according to the frame chassis space information includes:

[0079] S201: Divide the frame chassis into a first assembly area, a second assembly area, and a third assembly area according to the frame chassis space information, wherein the second assembly area is the area between two longitudinal beams, and the first assembly area and the third assembly area are symmetrically distributed on the left and right sides of the second assembly area.

[0080] S202: Determine the number of power battery packs in the first assembly area, the second assembly area, and the third assembly area.

[0081] S203: Determine the target size according to the spatial information of the first assembly area, the second assembly area, and the third assembly area and the number of power battery packs.

[0082] The frame chassis space is divided into three parts, resulting in three assembly areas. The spatial information of each assembly area is available, and the target size of the power battery pack can match the spatial information of each assembly area.

[0083] In specific applications, two power battery packs are set in each assembly area, and the two power battery packs are stacked up and down. After installation, the distance between the lower power battery pack and the ground can meet the up and down bump amplitude requirements of the vehicle during driving, avoiding bumps or bottoming. When designing the power battery pack of this solution, the size of the power battery pack is designed according to the frame chassis space, which can ensure that the power battery pack is installed on the frame chassis with sufficient ground clearance without occupying other space in the vehicle, thereby maximizing the vehicle space utilization.

[0084] Preferably, in the above solution, if there are multiple power battery packs in the first assembly area, the second assembly area, and the third assembly area, the method for designing a power battery pack further includes:

[0085] S2031: Determine an arrangement of the multiple power battery packs in the first assembly area, the second assembly area, and the third assembly area.

[0086] Specifically, each assembly area may include two power battery packs, which are stacked.

[0087] S2032: Determine the battery pack reinforcement according to the arrangement and the design information of the target battery pack model, wherein the design information includes the target weight of the target battery pack; the battery pack reinforcement includes a reinforcement structure for connecting different power battery packs in the same assembly area into a whole and a reinforcement structure for connecting different power battery packs in different assembly areas into a whole.

[0088] When stacking the power battery packs, the upper and lower layers are connected together using reinforcements. The upper battery pack is then attached to the longitudinal beams using assembly aids. Because the battery packs themselves are heavy and the longitudinal beams are located on one side of the pack, after assembly, the frame of the battery packs has weak areas that are easily deformed due to gravity and other factors. Reinforcements are installed in these weak areas to improve the stability of the frame structure.

[0089] An embodiment of the present application also provides a computer program product, in which program instructions are stored. After a computer or processor reads the program instructions, it executes the method for designing a power battery pack for an electric heavy truck as described in any of the above method embodiments.

[0090] The present application also provides a power battery pack designed using the above-described design method, comprising a battery pack housing and a cell module disposed within the battery pack housing. As shown in Figures 2-5 , the battery pack housing comprises a support frame 100, a box member 200 that seals the gaps in the support frame, an upper cover 300, and a bottom plate 400.

[0091] FIG2 shows a schematic diagram of a two-layer support frame 100 stacked one above the other. The support frame 100 is a rectangular parallelepiped frame formed by assembling frame structural members 101. Each corner of the rectangular parallelepiped frame serves as a weak point. Each weak point is equipped with a first reinforcement member 102 that matches the shape of the corner. The first reinforcement member 102 shown in the figure includes: a first angle plate disposed at the corner of the upper surface of the rectangular parallelepiped frame; a second angle plate disposed at the corner of the lower surface of the rectangular parallelepiped frame; and a first connecting plate connecting the first and second angle plates. Because the corners are right angles, the first and second angle plates are both right angles, and both sides of the angle plates have the same length. Preferably, as shown in FIG2 , the first reinforcement member 102 includes a chamfered corner 1021. This can be rounded and formed during the processing of the first reinforcement member 102. Compared to a right angle, a chamfered corner provides a smoother transition at the connection and more uniform force distribution, thereby improving the stability of the corner area.

[0092] The box member 200 can be an aluminum skin, which is welded to the support frame 100 to achieve a sealed seal. The support frame 100 can be fixed together by multiple connecting rods and bolts. There will be a certain gap between the different connecting rods. After the size of the skin matches the gap size, it is fixed by welding.

[0093] The upper cover 300 can be fixed to the support frame 100 by bolts. As shown in FIG. 2 , after the upper cover 300 is sealed and connected to the support frame 100 , it can cover the surface of the support frame 100 .

[0094] As shown in Figure 4, the base plate 400 can also be used to arrange cooling system pipes and other equipment. The base plate 400 is designed to be slightly larger than the bottom of the support frame 100, allowing the support frame 100 to be placed directly on the base plate 400 and surrounded by the edge of the base plate 400. Installing the base plate 400 allows sufficient space to be reserved for the installation of the battery cell modules after the battery cell module arrangement step is completed.

[0095] As shown in Figures 2, 3 and 6, the internal space of the rectangular frame is divided into at least two accommodating compartments, and a support frame 105 is set between two adjacent accommodating compartments; in the present application, the support frame 105 in the rectangular frame includes one, that is, the internal space of the rectangular frame is divided into two accommodating compartments. A second reinforcement member 103 is set on the rectangular frame at a position opposite to the support frame 105; the second reinforcement member 103 includes: a first T-shaped plate set on the upper edge of the rectangular frame, a second T-shaped plate set on the lower edge of the rectangular frame, and a second connecting plate connecting the first T-shaped plate and the second T-shaped plate; screw holes 1031 are provided at corresponding positions of the support frame 105 and the second connecting plate, and the support frame 105 is fixedly connected to the second connecting plate after the positioning bolts are sequentially passed through the screw holes of the support frame and the second connecting plate. Through this solution, the battery cell module can be set in the accommodating compartment of the support frame 100. The smaller accommodating space can minimize the deformation of the battery cell module, thereby providing good protection for the battery cell module.

[0096] In conjunction with the support frame structure shown in Figures 7 and 8, the edges of the first and second connecting plates are formed with limiting portions, which are used to limit the position of the box component. In Figure 7, the first connecting plate is formed with a first limiting portion 1022, and in Figure 8, the second connecting plate is formed with a second limiting portion 1031. The two sides of the first and second connecting plates correspond to the gaps in the support frame. When the box component 200 needs to be welded to the support frame, the limiting portions can be used to limit the box component 200, facilitating operations such as welding or bonding.

[0097] As shown in conjunction with Figure 9 and Figure 2 , a ridge is formed on the second connecting plate of the second reinforcement member, and the screw holes on the second connecting plate are formed on the ridge, which is provided with a plurality of slots. The provision of the ridge and the provision of the screw holes on the ridge facilitate the positioning and installation of the support frame 105, and the provision of the plurality of slots on the ridge can reduce the overall weight of the second reinforcement member 102.

[0098] The power battery pack in the above scheme, after complete assembly, is provided with dual-pass seals only at the connection points between the base plate 400 and the support frame 100, the connection points between the upper cover 300 and the support frame 100, and the connection points between the box component 200 and the support frame 100. This dual-pass seal utilizes a double-layer sealing ring arrangement. As shown in Figure 5, the surface of the support frame 100 that connects to the upper cover 300 is a dual-pass sealing surface 104, on which the double-layer sealing ring is simply arranged. This method facilitates sealing operations and simplifies the overall structure of the resulting power battery pack.

[0099] In the above embodiments of the present application, in order to achieve the requirement of lightweight overall structure of the power battery pack, the selection of materials for each component can select lightweight profiles and processing technology on the premise of meeting the requirements. For example, the support frame 100 is used to undertake the installation of the power battery pack and its components on the vehicle, and at the same time transmit the road surface excitation generated during the operation of the vehicle, which can be achieved by welding aluminum extrusion profiles. The box component 200 is used for the installation and sealing of the battery module and its electrical parts, and can be made of aluminum plate, which is formed by extrusion. The first reinforcement 102 and the second reinforcement 103 are formed by casting or machining. The battery cover 300 is used to seal the top surface of the power battery pack. The bottom plate 400 is used to bond the battery module and provide cooling for the battery module at the same time, which can be achieved by aluminum alloy extrusion molding and aluminum profile welding.

[0100] The present application also provides a battery pack assembly comprising a plurality of the power battery packs described in the above embodiments. The number of power battery packs in the battery pack assembly can be determined based on the vehicle's power requirements and the energy density of the power battery packs.

[0101] As shown in Figures 6 to 9, the assembly relationship diagrams of the power battery pack and the frame chassis, the embodiment of the present application also provides a battery pack assembly, the number of the power battery packs includes three groups, one group of the power battery packs is arranged between the two longitudinal beams 600 of the frame chassis, and the other two groups of the power battery packs are symmetrically arranged on the left and right sides of the frame chassis; each of the power battery packs is fixedly connected to the longitudinal beam 600.

[0102] Taking the power battery pack assembly shown in Figure 6 as an example, each group of power battery packs includes two stacked power battery packs, which is equivalent to installing six power battery packs on the frame chassis. It can meet the vehicle's power needs, and after the power battery pack is installed, it is basically flush with the longitudinal beam as a whole, and will not occupy too much space above the chassis, thereby improving the vehicle's space utilization.

[0103] As shown in Figures 6 and 7, the battery pack assembly also includes a third reinforcement 505 for connecting different power battery packs in the same assembly area into a whole; different power battery packs in the same assembly area are stacked, and the third reinforcement 505 is arranged between the two layers of power battery packs. The third reinforcement 505 is fixedly connected to the lower surface of the upper power battery pack and the upper surface of the lower power battery pack by fixing members (such as bolts). As shown in Figure 7, the connection position of the third reinforcement 505 to the upper and lower power battery packs can correspond to the position of the first reinforcement 102. Through this solution, the connection components of the upper and lower power battery packs can be hidden, improving the integration of the entire structure.

[0104] Furthermore, the battery pack assembly also includes a first auxiliary component for connecting different power battery packs in different assembly areas into a whole. The different power battery packs in different assembly areas are arranged side by side and separated by longitudinal beams. The first auxiliary component connects the two side-by-side power battery packs while also fixing at least one power battery pack to the longitudinal beam. Referring to the structural schematics shown in Figures 8 and 9, each group of power battery packs contains two first auxiliary components, one at each end of the power battery pack.

[0105] As shown in Figures 6, 7 and 9, each of the first auxiliary parts includes a bending part and a clamping part. The clamping part is fixedly connected to a power battery pack; specifically, the bending part includes a first bending portion and a second bending portion formed in one piece; the first bending portion is fixed to another power battery pack and fixedly connected to the longitudinal beam; the second bending portion of the bending part extends to the bottom of the clamping part and is fixedly connected to the bottom of the clamping part. Referring to Figure 7, the power battery packs are defined as the first power battery pack, the second power battery pack and the third power battery pack from left to right, respectively. The first bending part and the first clamping part 504 are arranged between the first power battery pack and the second power battery pack, and the second bending part and the second clamping part 504' are arranged between the second power battery pack and the third power battery pack. As shown in the figure: the first clamp 504 is fixedly connected to one side of the second power battery pack; the first bending member includes an integrally formed first bending portion 502 and a second bending portion 503; the first bending portion 502 is fixed to the first power battery pack and fixedly connected to the longitudinal beam; the second bending portion 503 extends to the bottom of the first clamp 504 and is fixedly connected to the bottom of the first clamp 504. The second clamp 504' is fixedly connected to the other side of the second power battery pack; the second bending member includes an integrally formed third bending portion 502' and a fourth bending portion 503'; the third bending portion 502' is fixed to the third power battery pack and fixedly connected to the longitudinal beam; the fourth bending portion 503' extends to the bottom of the second clamp 504' and is fixedly connected to the bottom of the second clamp 504'. Through the above structure, all power battery packs can be installed on the longitudinal beam, and the above structure is compact and occupies little space.

[0106] Furthermore, in the above solution, the first bend portion is integrally formed with the frame of the supporting frame of the connected power battery pack. As shown in Figure 7, the first bend portion 502 is integrally formed with the front frame 501 of the supporting frame of the first power battery pack, and the third bend portion 502' is integrally formed with the front frame 501' of the supporting frame of the third power battery pack. This means that the assembly aid is integrally formed with a portion of the supporting frame, with no connection joints between the two, resulting in high rigidity, virtually no stress displacement at the joint surface, and high reliability.

[0107] As shown in Figures 6, 8, and 9, the battery pack assembly also includes a second auxiliary component 506, which is disposed outside the power battery pack and opposite the second reinforcement 103; the second auxiliary component 506 is fixedly connected to the longitudinal beam. As shown in Figure 9, through this solution, the power battery pack is connected to the longitudinal beam via three auxiliary components, with different auxiliary components located at positions corresponding to the corners and the middle support frame, respectively, to provide uniform support force. In addition, as a feasible solution, as shown in the figure, the above-mentioned second auxiliary component 506 can be located only on the power battery packs on both sides to reduce the number of components.

[0108] The solution in the above-mentioned embodiment of the present application combines the vehicle parameters of the electric heavy-duty truck to give a reasonable power battery pack model during the design phase of the power battery pack, thereby reducing the number of internal parts of the power battery pack from the source, so that the power battery pack can be assembled on the frame chassis while meeting the requirements of vehicle integration, lightweight, and maximum space utilization. The solution of this application redefines the fusion structural design of the heavy-duty truck power battery pack and the entire vehicle, and realizes the installation, protection, and sealing of the power battery pack. Through reasonable stress area division, the cell modules in the power battery pack are installed in a grid-like manner, and the reinforcement structure of the assembly points and weak areas is improved to make the power battery pack evenly stressed and the frame less likely to deform.

[0109] Obviously, the above embodiments are merely examples for clarity of explanation and are not intended to limit the implementation methods. Those skilled in the art will readily appreciate that other variations or modifications based on the above descriptions are possible. It is not necessary and impossible to enumerate all implementation methods here. Obvious variations or modifications arising therefrom remain within the scope of protection of this application.

Claims

1. A design method for a power battery pack for an electric heavy truck, characterized in that, it includes: Obtain the vehicle parameters of the electric heavy truck, where the vehicle parameters include weight information, working condition information, and frame chassis space information; Determine the selection of the battery cell module of the power battery pack according to the weight information and the working condition information, and determine the target size of the power battery pack according to the frame chassis space information; Generate an initial battery pack model according to the selection of the battery cell module, the target size, and preset functional components; the preset functional components include a cooling functional component, a sealing functional component, a bearing component, and a connecting component; Simulate the state of assembling the initial battery pack model to the frame chassis, and obtain the force simulation result of the initial battery pack model; Determine the assembly point information of the initial battery pack model and the weak area information of the initial battery pack model according to the force simulation result; Adjust the initial battery pack model, configure assembly auxiliary components at the assembly points, and configure strengthening components in the weak areas to obtain a target battery pack model.

2. The design method for a power battery pack for an electric heavy truck according to claim 1, characterized in that, The determining the target size of the power battery pack according to the frame chassis space information includes: Divide the frame chassis into a first assembly area, a second assembly area, and a third assembly area according to the frame chassis space information. The second assembly area is the area between two longitudinal beams, and the first assembly area and the third assembly area are symmetrically distributed on the left and right sides of the second assembly area; Determine the number of power battery packs in the first assembly area, the second assembly area, and the third assembly area; Determine the target size according to the space information of the first assembly area, the second assembly area, and the third assembly area and the number of power battery packs.

3. The design method for a power battery pack for an electric heavy truck according to claim 2, characterized in that, If the number of power battery packs in the first assembly area, the second assembly area, and the third assembly area is multiple, the method further includes: Determine the arrangement of the multiple power battery packs in the first assembly area, the second assembly area, and the third assembly area; Determine the battery pack assembly strengthening components according to the arrangement and the design information of the target battery pack model. The design information includes the target weight of the target battery pack; the battery pack strengthening components include a strengthening component structure for connecting different power battery packs in the same assembly area into a whole and a strengthening component structure for connecting different power battery packs in different assembly areas into a whole.

4. A computer program product, characterized in that, Program instructions are stored in the product, and a computer or a processor reads the program instructions and executes the design method for a power battery pack for an electric heavy truck according to any one of claims 1-3.

5. A power battery pack obtained by the design method for a power battery pack for an electric heavy truck according to any one of claims 1-3, characterized in that, It includes a battery pack housing and a battery cell module disposed within the battery pack housing; the battery pack housing includes a support skeleton, a bottom plate, a box body component that seals and plugs the gaps of the support skeleton, and an upper cover; wherein: The support skeleton is a rectangular parallelepiped frame, and each corner of the rectangular parallelepiped frame is a weak area; a first reinforcing member matching the shape of the corner is assembled at each weak area; The first reinforcing member includes: a first angle plate disposed at the corner of the upper surface of the rectangular parallelepiped frame, a second angle plate disposed at the corner of the lower surface of the rectangular parallelepiped frame, and a first connecting plate connecting the first angle plate and the second angle plate.

6. The power battery pack according to claim 5, characterized in that: The internal space of the rectangular parallelepiped frame is divided into at least two accommodation compartments, and a support frame is provided between adjacent two accommodation compartments; A second reinforcing member is provided at a position of the inner wall of the rectangular parallelepiped frame opposite to the support frame; the second reinforcing member includes: a first T-shaped plate disposed on the upper border of the rectangular parallelepiped frame, a second T-shaped plate disposed on the lower border of the rectangular parallelepiped frame, and a second connecting plate connecting the first T-shaped plate and the second T-shaped plate; Screw holes are formed at corresponding positions of the support frame and the second connecting plate, and the support frame and the second connecting plate are fixedly connected by sequentially passing a positioning bolt through the screw holes of the support frame and the second connecting plate.

7. The power battery pack according to claim 6, characterized in that: Limit portions are formed at the edges of the first connecting plate and the second connecting plate, and the limit portions are used for limiting the box body component.

8. The power battery pack according to claim 6, characterized in that: A convex rib is formed on the second connecting plate, the screw hole on the second connecting plate is formed on the convex rib, and a plurality of hole grooves are formed on the convex rib.

9. The power battery pack according to any one of claims 5-8, characterized in that: Double seals are provided at the positions where the bottom plate is connected to the support skeleton, where the upper cover is connected to the support skeleton, and where the box body component is connected to the support skeleton.

10. A battery pack assembly, characterized in that, It includes a plurality of power battery packs according to any one of claims 5-9.

11. The battery pack assembly according to claim 10, characterized in that: The plurality of power battery packs are divided into three groups, one group of power battery packs is disposed between two longitudinal beams of the vehicle frame chassis, and the other two groups of power battery packs are symmetrically disposed on the left and right sides of the vehicle frame chassis; Each group of power battery packs is fixedly connected to the longitudinal beam.

12. The battery pack assembly according to claim 11, characterized in that, It further includes: A third reinforcing member for connecting different power battery packs in the same assembly area; Wherein, different power battery packs in the same assembly area are stacked, the third reinforcing member is disposed between two layers of power battery packs, and the third reinforcing member is fixedly connected to the lower surface of the upper layer of power battery pack and the upper surface of the lower layer of power battery pack respectively through fixing members.

13. The battery pack assembly according to claim 11, characterized in that, It further includes: The first auxiliary part is used to connect different power battery packs in different assembly areas; wherein, the different power battery packs in different assembly areas are arranged side by side and separated by a longitudinal beam, and the first auxiliary part connects two power battery packs arranged side by side and fixedly connects at least one power battery pack to the longitudinal beam.

14. The battery pack assembly according to claim 13, characterized in that: the first auxiliary part is arranged at both ends of the power battery pack, and each first auxiliary part includes a bending part and a clamping part; the clamping part is fixedly connected to one power battery pack; the bending part includes a first bending part and a second bending part integrally formed; the first bending part is fixed on another power battery pack and fixedly connected to the longitudinal beam; the second bending part extends to the bottom of the clamping part and is fixedly connected to the bottom of the clamping part.

15. The battery pack assembly according to claim 14, characterized in that: the first bending part is integrally formed with the support frame border of the connected power battery pack.

16. The battery pack assembly according to any one of claims 13-15, characterized in that, further comprising: a second auxiliary part, arranged outside the power battery pack and fixedly connected to the longitudinal beam, and the second auxiliary part is arranged opposite to the second strengthening part.

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