Battery Pack Coupling Layout for Tolerance-Robust Heavy Vehicle Assembly
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Solution Overview
Problem
Existing battery pack systems for electrified heavy-duty vehicles are sensitive to tolerance variations, require complex and time-consuming assembly processes, and occupy large surfaces, making them inefficient and costly.
Innovation Solution
A battery pack system with a coupling mechanism featuring a first and second coupling member configured to transfer torques and translational forces, allowing for efficient docking and simplified assembly/disassembly, and a lock device to prevent separation, reducing sensitivity to tolerance variations and optimizing surface usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional battery pack docking systems are used, then the system can connect multiple battery packs, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The docking system is segmented into separate coupling members: a first coupling member integrated into the battery pack casing and a second coupling member on the docking station. This segmentation allows independent optimization of each component and simplifies the overall assembly process by enabling modular connection.
Solution Approach 2:
The coupling members act as intermediary elements that mediate the connection between battery packs and the docking station. These intermediaries transfer torques and translational forces, enabling efficient force transmission while simplifying the docking interface and reducing assembly complexity.
2Reliability
If traditional docking systems are used, then battery packs can be connected, but the system becomes sensitive to tolerance variations
Solution Approach 1:
The coupling members are pre-integrated into the battery pack casing and docking station structure during manufacturing. This preliminary integration ensures proper alignment and reduces sensitivity to tolerance variations during final assembly, as the coupling interfaces are already positioned and oriented correctly.
Solution Approach 2:
The coupling members incorporate spherical or curved contact surfaces that provide self-aligning capabilities. This geometric feature compensates for tolerance variations by allowing automatic alignment through the curved interfaces, reducing the impact of manufacturing tolerances on docking reliability.
3Area of stationary object
If traditional docking systems are used, then battery packs can be docked, but large surfaces are occupied
Solution Approach 1:
The coupling members utilize three-dimensional spatial optimization by extending connection points vertically and laterally from the battery pack casing. This dimensional approach allows force transmission through multiple axes, reducing the horizontal footprint required for docking while maintaining structural integrity.
Solution Approach 2:
The docking system is divided into distributed coupling points rather than a single large docking surface. Multiple smaller coupling members are positioned at optimized locations on the battery pack casing, reducing the total occupied surface area while providing sufficient structural support for force transmission.
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 enhances the robustness and efficiency of battery pack assembly, reduces assembly time, and minimizes the impact of tolerance variations, resulting in a cost-effective and reliable battery pack system.
Implementation Method 1
The first coupling member and the second coupling member may be coupled by an interference fit
Implementation Method 2
the coupling is configured to transfer torques and translational forces between the first battery pack and the second battery pack
Data Source
AI summary
A battery pack system includes a first battery pack including a first casing and a plurality of battery modules arranged inside the first casing; a second battery pack including a second casing and a plurality of battery modules arranged inside the second casing; and a coupling including a first coupling member fixed to the first casing, and a second coupling member fixed to the second casing, the first coupling member being configured to mate with the second coupling member; wherein the coupling is configured to transfer torques and translational forces.