Battery Pack Mounting Assembly Vibration Control
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Solution Overview
Problem
Conventional mounting systems for high voltage battery packs in electrified vehicles fail to adequately address noise, vibration, and harshness requirements, leading to suboptimal vibration characteristics and potential safety issues.
Innovation Solution
A mounting assembly comprising a primary bracket and a support bracket, where the support bracket is secured between the battery pack and the primary bracket to increase stiffness, featuring a Z-shaped or C-shaped configuration with notches and weld beads to enhance vibrational performance and safety, while allowing for energy dissipation during impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mounting systems are used to attach battery packs to vehicle frames, then the mounting system is simple and easy to manufacture, but the vibration characteristics and noise requirements are not adequately met
Solution Approach 1:
The mounting system is divided into separate functional components: primary brackets for structural attachment to the vehicle frame, support brackets for additional stabilization, and isolation elements for vibration damping. This segmentation allows each component to be optimized for its specific function while collectively meeting the vibration and noise requirements without excessive overall complexity
Solution Approach 2:
The mounting system employs composite construction combining rigid bracket materials (metal) for structural strength with flexible isolation materials (rubber, foam, or spring elements) for vibration damping. This composite approach enables the system to simultaneously achieve the required vibration characteristics while maintaining manufacturability and controlled complexity
2Ease of manufacture
If the mounting system is made simpler for ease of manufacture, then manufacturing cost and complexity are reduced, but safety and durability requirements may not be met
Solution Approach 1:
The mounting system incorporates pre-engineered attachment points, pre-formed bracket geometries, and pre-selected isolation elements that are designed to work together as an integrated system. This preliminary design approach ensures that safety and durability requirements are built into the structure before manufacturing, allowing for straightforward fabrication while meeting stringent reliability standards
Solution Approach 2:
The mounting system utilizes standardized parameters for bracket dimensions, material properties, and isolation element characteristics that have been optimized through engineering analysis. By establishing fixed parameter ranges and specifications, the system achieves both ease of manufacture through standardization and reliability through proven design parameters
Data Source
AI summary
An electrified vehicle includes a vehicle frame, a battery pack mounted to the vehicle frame, a primary bracket secured to each of the vehicle frame and the battery pack, and a support bracket secured to the battery pack and the primary bracket. The support bracket increases the stiffness of the primary bracket.