Battery Pack Coupling Assembly for Tolerance-Robust Chassis Docking
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Solution Overview
Problem
Existing battery pack systems for electrified heavy-duty vehicles are sensitive to tolerance variations and require complex and time-consuming assembly processes due to the use of multiple hole/pin pairs, which occupy large surfaces and are prone to assembly errors.
Innovation Solution
A battery pack system featuring a coupling mechanism with a first and second coupling member configured to transfer torques and translational forces, allowing for efficient docking and simplified assembly/disassembly, with a lock device to prevent separation, and a compact design that reduces sensitivity to tolerance variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple hole/pin pairs are used for docking battery packs, then the connection strength is improved, but the device complexity and assembly time increase
Solution Approach 1:
The patent combines multiple hole/pin pairs into a single coupling member that integrates multiple connection functions. This coupling member includes a body with a first hole for a first pin and a second hole for a second pin, consolidating what would otherwise be separate docking components into one unified structure that maintains connection strength while reducing assembly complexity
Solution Approach 2:
The coupling member serves multiple functions simultaneously: it provides structural connection through multiple holes, defines precise docking geometry through its body shape, and enables tolerance compensation through its design. This multi-functional approach replaces multiple specialized components (multiple separate hole/pin assemblies) with a single universal coupling member
2Reliability
If multiple hole/pin pairs are used for docking battery packs, then the connection reliability is improved, but the loss of time during assembly increases
Solution Approach 1:
The coupling member is pre-configured with multiple holes and pins in specific positions and orientations before assembly. This preliminary preparation of the coupling geometry allows for rapid docking without requiring sequential alignment of multiple separate components, thus maintaining connection reliability while reducing assembly time
Solution Approach 2:
The coupling member acts as an intermediary component that mediates the docking between battery pack units. It includes reference surfaces and geometric features that facilitate automatic alignment and positioning, reducing the time required for precise positioning while ensuring reliable connection through its structured design
3Strength
If a rigid coupling structure is used to transfer torques and forces, then the mechanical strength is improved, but the sensitivity to tolerance variations increases
Solution Approach 1:
The coupling member incorporates geometric parameters and reference surfaces designed to accommodate tolerance variations. The body of the coupling member includes specific dimensional relationships and angular orientations that maintain mechanical strength while compensating for manufacturing tolerances in the connected battery pack units
Solution Approach 2:
The coupling design includes built-in tolerance compensation features that cushion against the effects of manufacturing variations. The reference surfaces and geometric constraints are designed to absorb tolerance stack-ups before they affect the mechanical connection, maintaining strength while reducing sensitivity to precision requirements
Data Source
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AI summary
A battery pack system (18; 20) comprising a first battery pack (28a; 30a) including a first casing (34a; 36a) and a plurality of battery modules (48) arranged inside the first casing (34a, 36a); a second battery pack (28b, 30b) including a second casing (34b; 36b) and a plurality of battery modules (48) arranged inside the second casing (34b; 36b); and a coupling (42) including a first coupling member (50a) fixed to the first casing (34a, 36a), and a second coupling member (50b) fixed to the second casing (34b; 36b), the first coupling member (50a) being configured to mate with the second coupling member (50b); wherein the coupling (42) is configured to transfer torques and translational forces. A chassis arrangement (12), an electrified heavy-duty vehicle (10) and a method of assembling a battery pack system (18; 20) are also provided.