Battery Pack Mounting Rack Layout for Heavy Truck Chassis Integration
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Solution Overview
Problem
The existing bottom-mounted battery pack assembly structure in new-energy heavy truck commercial vehicles increases assembly complexity, weight, and maintenance difficulty, leading to performance degradation, energy inefficiency, and high costs due to decentralized battery casings and complex connections.
Innovation Solution
A mounting rack for battery packs is designed with a first assembly unit and a second assembly unit, featuring transverse and longitudinal beams that connect to the vehicle chassis, providing symmetrical accommodation cavities for the battery pack, enhancing stability and torsional resistance, and using floating nuts for secure connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple standard boxes or small battery casings are combined to cope with huge power demand, then the power demand can be met, but the assembly complexity and production time increase significantly
Solution Approach 1:
The patent merges multiple battery casings into a single integrated battery pack structure that is mounted as one unit on the vehicle chassis. This integration maintains the required power capacity while eliminating the complexity of assembling multiple separate casings, as the battery pack is installed as a complete assembly rather than through step-by-step combination of individual units.
2Power
If multiple battery casings are combined, then the power demand can be met, but the production time increases due to complex assembly process
Solution Approach 1:
The battery pack is pre-assembled and pre-integrated into a complete unit before being mounted on the vehicle. This preliminary preparation of the battery pack as a finished assembly enables rapid installation on the chassis, significantly reducing production time compared to assembling multiple separate battery casings during the vehicle manufacturing process.
3Power
If multiple battery casings are used, then the power demand can be met, but the weight of the vehicle increases due to additional supports required
Solution Approach 1:
The patent combines multiple battery casings into a single integrated battery pack that utilizes the vehicle chassis structure for support rather than requiring additional dedicated support components for each individual casing. This merging approach reduces the total weight of supporting structures needed while maintaining the required power capacity.
Data Source
AI summary
Provided are a mounting rack for a battery pack, and a vehicle. The mounting rack includes a first assembly unit and a second assembly unit. The first assembly unit is disposed between two chassis beams and includes first transverse beams, first longitudinal beams, and first assembly members. Two adjacent first transverse beams and the two chassis beams located therebetween define a first accommodation cavity. The second assembly unit is disposed at a side of each chassis beam away from the first assembly unit and includes second transverse beams, second longitudinal beams, outer side beams, and second assembly members. Two second transverse beams, the chassis beam located therebetween, and the outer side beams define a second accommodation cavity. The first and second assembly members are both configured to connect the battery pack. The chassis beam is provided with at least one of the first longitudinal beam and the second longitudinal beam.