Commercial Vehicle Battery Mounting for Chassis Torsion Isolation
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Solution Overview
Problem
Commercial electric vehicles with rigidly attached battery structures face flexibility issues due to chassis torsion, leading to deformation and inadequate protection during accidents such as frontal crashes, side collisions, and rollovers.
Innovation Solution
A battery structure with resiliently deformable arrangements and fixation points that decouple the battery from the chassis, providing a three-point mounting system to absorb torsion and enhance crash protection, including a damping device for vertical vibrations and side crash protection members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the battery is rigidly mounted on the chassis, then the battery structure provides sufficient strength and stability, but the battery undergoes large deformation (30-50 mm) due to chassis torsion
Solution Approach 1:
The mounting system is segmented into two distinct parts: a first bracket rigidly attached to the chassis and a second bracket resiliently attached to the first bracket. This segmentation allows each part to perform its specific function - the first bracket provides rigid structural support while the second bracket accommodates chassis torsion through resilient deformation, thereby reducing battery deformation to minimal levels.
Solution Approach 2:
The second bracket acts as an intermediary element between the rigid first bracket and the battery. It absorbs chassis torsion through its resilient attachment to the first bracket, preventing this deformation from being transmitted to the battery. This intermediary resiliently deformable arrangement serves as a buffer that protects the battery from chassis-induced deformation.
2Manufacturing precision
If the battery is mounted with resiliently deformable arrangements to reduce deformation, then the battery is protected from chassis torsion, but the battery structure may lack sufficient protection during accidents
Solution Approach 1:
Different parts of the mounting system have different mechanical properties tailored to their specific functions. The first bracket features a rigid attachment to the chassis for structural strength, while the second bracket has a resilient attachment to the first bracket for deformation absorption. This local differentiation of rigidity allows the system to simultaneously achieve both deformation reduction and crash protection.
Solution Approach 2:
The mounting system transitions from a static rigid connection to a dynamic resilient connection. The second bracket's resilient attachment allows it to adapt its stiffness based on loading conditions - remaining flexible during normal operation to absorb torsion, while providing structural support during crash events. This dynamic behavior enables the system to satisfy both contradictory requirements.
3Manufacturing precision
If the battery is mounted vertically behind the cab to reduce deformation, then the distance between attachment points is shortened, but the battery loses flexibility and crash protection
Solution Approach 1:
Instead of reducing deformation by shortening the longitudinal distance between brackets (vertical mounting), the invention addresses deformation by introducing a new dimension of resilience in the transverse mounting arrangement. The second bracket's resilient attachment to the first bracket provides deformation absorption without constraining the battery's horizontal positioning, thereby maintaining chassis flexibility while achieving deformation reduction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively decouples the battery from chassis torsion, ensuring sufficient stiffness and strength to withstand crash forces while minimizing deformation and providing enhanced protection during accidents.
Implementation Method 1
the resiliently deformable arrangement through which the battery is mounted on the first bracket
Implementation Method 2
including a damping device for vertical vibrations
Data Source
AI summary
Commercial vehicle comprising a chassis adjoining a cab along a longitudinal direction (X), the commercial vehicle being at least partly electrically powered, wherein the commercial vehicle has at least one battery structure (30) rigidly attached to the chassis to accommodate a battery, the battery structure (30) comprising first (31) and second (32) brackets extending in a transverse direction (Y) at a distance from each other along the longitudinal direction (X), wherein the battery structure (30) comprises at least one resiliently deformable arrangement (50) through which the battery (21) is mounted on the first bracket (31), and at least one fixation arrangement (60) through which the battery (21) is rigidly mounted on the second bracket (32).