Battery Pack Support Bracket With Modular Spacer for Ladder Frames
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Solution Overview
Problem
Existing vehicle battery pack support devices for electric trucks are heavy and costly due to the need for robust components to securely support large battery packs, and they require different designs for varying vehicle classes, leading to increased production costs.
Innovation Solution
A vehicle battery pack support device that includes a frame-side bracket secured to the outer side face of the ladder frame's side rail, an elastic coupling part to connect the battery pack and the frame-side bracket, and a spacer with lower extensions that interposes between the side rail and the frame-side bracket, allowing for adjustable width to accommodate different vehicle classes without altering the support device's configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If robust components are used to securely support large battery packs, then reliability is improved, but weight increases
Solution Approach 1:
The support device is divided into multiple bracket parts (first bracket part, second bracket part, third bracket part) that can be selectively assembled. This segmentation allows the system to achieve reliable support through strategic placement of robust components only where needed, rather than making the entire support structure heavy and robust throughout.
Solution Approach 2:
Different parts of the support device have different structural qualities tailored to their specific functions. The first bracket part has a reinforcement plate for high-stress areas, while other parts use standard bracket structures. This local differentiation ensures reliability at critical points while minimizing overall weight.
2Adaptability or versatility
If the support device is designed for each vehicle class, then adaptability is improved, but manufacturing cost increases
Solution Approach 1:
The support device uses a universal set of bracket parts that can be configured for different vehicle classes. The first bracket part, second bracket part, and third bracket part can be selectively assembled in different combinations to accommodate various side rail distances and vehicle specifications, allowing one universal component set to serve multiple vehicle types.
Solution Approach 2:
The support device configuration is dynamic and adaptable rather than fixed. The selective assembly of different bracket parts allows the same component set to be reconfigured for different vehicle classes, enabling the system to adapt to varying requirements without requiring completely different designs for each vehicle type.
3Device complexity
If multiple bracket parts are selectively assembled, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The design extracts and separates the support function into distinct, standardized bracket parts with predefined mounting positions. By taking out the complexity of customization and providing standardized interfaces and grid-pattern bolt fastening parts, the system reduces overall device complexity while maintaining manageable manufacturing precision requirements through modular assembly.
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 support device effectively reduces weight and costs by using a modular spacer design that can be easily adjusted to fit various vehicle classes, ensuring reliable support for large battery packs while minimizing material usage and production complexity.
Implementation Method 1
an elastic coupling part elastically coupling the battery pack and the frame-side bracket
Data Source
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AI summary
Provided is a vehicle battery pack support device applicable to various classes of vehicles and allowing weight reduction and cost reduction. A vehicle battery pack support device 80 for suspending a battery pack 70 at a side rail 11 constituting a ladder frame 10 of a vehicle 1 includes: a frame-side bracket 81 secured, by bolts 11B, to an outer side face of the side rail 11 at a plurality of bolt fastening parts 11H thereof arrayed in a grid arrangement; an elastic coupling part 83 elastically coupling the battery pack 70 and the frame-side bracket 81; and a spacer 84 interposed between the outer side face of the side rail 11 and the frame-side bracket 81. The spacer 84 includes a plurality of columnar members 90 corresponding to the plurality of bolt fastening parts 11H, and a connecting part 91 connecting the plurality of columnar members 90.