EV Battery Holder Position Sensing for Load-Balanced Locking
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Solution Overview
Problem
Existing battery pack installation methods in electric vehicles suffer from stress concentration on lock mechanisms, leading to reduced service life and unreliable electrical connections, making it difficult to achieve synchronous locking and electrical connection reliability.
Innovation Solution
A battery holder with a fixing bracket and lock mechanism that distributes the weight of the battery pack across multiple supporting devices and a lock mechanism, ensuring even force distribution and improved connection strength, while also integrating sensors for precise positioning and reliable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery pack weight is supported only by the lock mechanism, then the locking function is achieved, but the lock mechanism experiences stress concentration and reduced service life
Solution Approach 1:
The support function is segmented from the locking function. Multiple supporting devices are introduced to bear the battery pack weight, while the lock mechanism专注于locking function only. This functional segmentation eliminates stress concentration on the lock mechanism and extends its service life.
Solution Approach 2:
The support function is transferred from the vertical dimension (where the lock mechanism operates) to additional support points distributed across the fixing bracket. This dimensional redistribution of load-bearing responsibilities prevents overload on the lock mechanism.
2Reliability
If the lock mechanism and electrical connection device are arranged independently, then each component is simple in structure, but synchronous locking and electrical connection reliability cannot be achieved
Solution Approach 1:
The lock mechanism and electrical connection device are merged into an integrated assembly where the electrical connection device is positioned within the lock mechanism structure. This ensures that locking and electrical connection occur simultaneously and reliably, while the overall structural complexity remains manageable through shared components.
Solution Approach 2:
The fixing bracket serves multiple functions: it provides structural support, mounts the lock mechanism, positions the electrical connection device, and ensures proper alignment between battery pack and holder. This multi-functionality reduces the need for separate components and simplifies the overall system.
Data Source
AI summary
Provided are a battery holder, a power transfer device, an electric vehicle and an installation method for electric vehicle. The battery holder includes a fixing bracket, the fixing bracket has an upper-position accommodation cavity, an upper-position sensor is arranged in the upper-position accommodation cavity, the upper-position sensor is used for detecting the supporting portion of the battery pack, so as to determine whether the battery pack has been installed in place relative to the battery holder in the height direction of the electric vehicle; and/or, the fixing bracket has a front-position accommodation cavity, a front-position sensor is arranged in the front-position accommodation cavity, the front-position sensor is used to detect the supporting portion of the battery pack, so as to determine whether the battery pack is installed in place relative to the battery holder in the length direction of the electric vehicle.