Aluminum Alloy Frame Integration for Detachable Power Cell Compartments
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Solution Overview
Problem
Existing electric commercial vehicles in China face challenges in achieving structural lightweight due to the use of high-strength steel frames, which also lead to poor handling stability and driving safety, as well as difficulties in mounting power cell compartments efficiently.
Innovation Solution
An aluminum alloy frame and power cell compartment integration structure is developed, featuring left and right longitudinal beams and cross beams arranged in a specific manner to accommodate the power cell compartment, which is detachably assembled between the longitudinal beams, facilitating charging and cell replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-strength steel is used for the frame, then the frame strength is improved, but the vehicle weight increases and structural lightweight cannot be achieved
Solution Approach 1:
The patent changes the material parameter from high-strength steel to aluminum alloy, which has lower density and higher specific strength. This material substitution allows the frame to maintain required strength while significantly reducing weight, achieving structural lightweight for electric commercial vehicles
Solution Approach 2:
The patent employs aluminum alloy as a composite material solution, utilizing its unique combination of low density and high specific strength to replace traditional steel materials, thereby resolving the contradiction between frame strength and vehicle weight
2Ease of manufacture
If the power cell compartment is mounted on the rear side of the cab, then the mounting position is simplified, but the center of mass height increases and handling stability deteriorates
Solution Approach 1:
The patent transitions the power cell compartment mounting from vertical arrangement (rear side of cab) to horizontal arrangement (front end of frame). This spatial reconfiguration lowers the center of mass height while maintaining mounting simplicity, thereby improving handling stability
3Adaptability or versatility
If the power cell compartment is hung on the left and right sides of the frame, then the mounting flexibility is improved, but the space for fuel tank and exhaust muffler is occupied and vehicle layout becomes complex
Solution Approach 1:
The patent extracts the power cell compartment from the traditional side-mounting position and relocates it to the front end of the frame. This separation of functions clears the side spaces for fuel tank and exhaust muffler installation, simplifying the overall vehicle layout while maintaining mounting flexibility
4Strength
If traditional steel frame structure is used, then the structural strength is sufficient, but the structural lightweight cannot be achieved and aluminum alloy forming advantages are not utilized
Solution Approach 1:
The patent changes the material parameter from steel to aluminum alloy, utilizing aluminum's lower density and higher specific strength. This parameter change enables structural lightweight while maintaining sufficient strength, and allows exploitation of aluminum alloy's diversified forming capabilities
Data Source
AI summary
The present disclosure discloses an aluminum alloy frame and power cell compartment integration structure, including an aluminum alloy frame and a power cell compartment. The aluminum alloy frame includes left and right longitudinal beams and several cross beams; the power cell compartment includes left and right supports, a bottom plate, a framework, an upper cover, and a charging port; the left and right supports, the upper cover and the bottom plate are respectively mounted on two side surfaces, a top and a bottom of the framework; a power cell is assembled in the framework of the power cell compartment; the charging port connected to the power cell is formed in the framework; and the power cell compartment is detachably assembled between the left and right longitudinal beams of the aluminum alloy frame through the left and right supports on the two side surfaces of the framework.