Battery Support Crossmember for Shorter Truck Wheelbase
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Solution Overview
Problem
Truck designs in certain jurisdictions face challenges due to load and dimension restrictions, leading to a large gap between the cab and trailer, which increases drag force and decreases fuel efficiency.
Innovation Solution
A chassis crossmember with a battery support is introduced, featuring a battery tray extending between the left and right chassis rails, and mounting brackets for rigid attachment, thereby increasing the stiffness of the vehicle chassis and reducing the wheelbase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the wheelbase is reduced to decrease the gap between cab and trailer, then fuel efficiency is improved, but the fuel tank size must be reduced
Solution Approach 1:
The battery support structure utilizes the vertical dimension by positioning the battery tray between the chassis rails, allowing the fuel tank to extend further back in the longitudinal dimension without increasing overall vehicle length. This dimensional rearrangement enables reduced wheelbase for better aerodynamics while preserving fuel capacity.
Solution Approach 2:
The chassis structure is segmented into distinct functional zones: the battery support occupies the central region between chassis rails, while the fuel tank is positioned in the rear section. This segmentation allows independent optimization of each component's position, enabling wheelbase reduction without compromising fuel tank volume.
2Strength
If mounting brackets are used to rigidly attach battery support to chassis rails, then chassis stiffness is increased, but device complexity increases
Solution Approach 1:
The mounting brackets are designed to merge the battery support structure with the existing chassis rails, utilizing the rails' inherent strength. The brackets integrate the battery tray, side plates, and mounting features into a unified assembly that leverages the chassis structure for stiffness without requiring separate complex reinforcement elements.
Solution Approach 2:
The mounting brackets serve multiple functions: they attach the battery support to the chassis rails, provide structural reinforcement to increase chassis stiffness, and offer mounting points for electrical connections and drainage systems. This multi-functionality reduces the need for additional separate components.
Data Source
AI summary
Aspects of the disclosure relate to chassis crossmember with a battery support. In certain embodiments, the chassis crossmember includes a battery support configured to mount at least one vehicle battery to and increase a stiffness of a chassis of a vehicle. The battery support includes a battery tray, including a floor, a front sidewall, and a rear sidewall. The battery tray is configured to extend between a left rail and a right rail of the chassis. The chassis crossmember further includes at least one left mounting bracket configured to rigidly mount a left side of the battery support to a left inner surface of the left rail of the chassis. The chassis crossmember further includes at least one right mounting bracket configured to rigidly mount a right side of the battery support to a right inner surface of the right rail of the chassis.