Power Battery Mounting Structure With Dual Load Paths
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Solution Overview
Problem
Existing vehicle power battery installation structures face issues with low reliability due to single load transmission paths, poor stress distribution, and inefficient adaptability to different vehicle models, leading to prolonged redesign times and reduced durability.
Innovation Solution
A power battery installation structure featuring multiple load transmission paths through upper and lower crossbeams, reinforced installation plates, and adaptable mounting surfaces to distribute stress evenly and facilitate rapid model adaptation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the power battery is installed on a single lower crossbeam with one force transmission path, then the installation structure is simple, but the overall reliability of the vehicle is low due to heavy load on a single path
Solution Approach 1:
The single force transmission path is segmented into multiple paths by introducing an upper crossbeam in addition to the lower crossbeam. The power battery load is now distributed through both crossbeams to the rear longitudinal beam, creating parallel force transmission paths that improve reliability without excessive complexity
Solution Approach 2:
The upper crossbeam and lower crossbeam are merged into a unified force transmission system that works together to support the power battery. This combination creates redundant load paths, ensuring that if one path is compromised, the other can still support the battery
2Ease of operation
If an adapter bracket is added to install the battery to the crossbeam, then the battery can be mounted, but the adapter bracket becomes a cantilever structure in a poor stress state
Solution Approach 1:
The problematic adapter bracket is extracted and replaced with a power battery installation plate that is directly integrated with the crossbeam structure. This eliminates the cantilever stress issue by providing direct mounting surfaces on the crossbeams without requiring separate adapter components
Solution Approach 2:
The power battery installation plate serves multiple functions: it provides mounting surfaces for the battery, integrates with both upper and lower crossbeams for load distribution, and eliminates the need for separate adapter brackets. This multi-functional design improves both installation feasibility and structural strength
3Strength
If the crossbeam position is moved forward to improve stress state, then the stress state improves, but the crossbeam and rear suspension installation point become staggered, making the frame not conducive to bearing impact loads
Solution Approach 1:
The solution moves from a single-dimensional adjustment (moving the crossbeam forward or backward) to a two-dimensional approach by utilizing both upper and lower crossbeams at different positions. This allows the system to maintain optimal stress states while preserving proper alignment with the rear suspension for impact load bearing
4Adaptability or versatility
If the crossbeam position is changed to match new vehicle models, then the structure adapts to new models, but the original power battery structure needs modification and redesign time increases
Solution Approach 1:
The power battery installation plate is designed as a universal component that can adapt to different crossbeam configurations across various vehicle models. The plate can be positioned and mounted on different crossbeam arrangements without requiring complete redesign of the power battery structure, thus improving model adaptability while reducing redesign time
Data Source
AI summary
A vehicle and a power battery installation structure are provided, each includes a rear longitudinal beams; a lower crossbeam with ends connecting the rear longitudinal beams; an upper crossbeam with ends connecting the rear longitudinal beams, the upper crossbeam and the lower beam arranged in sequence from front to rear of a vehicle; and a power battery installation plate below the upper crossbeam and connecting the upper crossbeam, the rear end of the power battery installation plate connected to the lower crossbeam. Load received by the power battery installation plate may be transmitted along two paths, so that the crossbeam structure of the vehicle body is more evenly stressed. The power battery installation plate may be modified to match different battery structures, thus increasing efficiency of vehicle model development and use rate of components.