Battery Pack Tray Locking Shaft Structure for Stable EV Swapping
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Solution Overview
Problem
The existing battery pack tray locking mechanism in electric vehicles is prone to disengagement due to single-end fixation, leading to instability and separation from the vehicle body, especially on rough roads, causing failure and safety concerns.
Innovation Solution
A battery pack tray with a frame body featuring multiple placing positions and a locking matching structure comprising a horizontally arranged locking shaft connected to first and second connecting plates, ensuring stable locking even if offset, and a reinforcing U-shaped structure for enhanced strength, along with a second electrical connector for efficient battery swapping without the need for additional space or lifting devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-end fixed locking matching structure is used, then the structure is simple, but the locking connection is unstable and easy to disengage on rough roads
Solution Approach 1:
The locking matching structure is segmented into multiple independent locking shafts (at least two) instead of a single locking point. Each locking shaft is independently connected to the frame body through connecting plates, creating multiple discrete locking points that distribute the locking force and prevent single-point failure on rough roads.
Solution Approach 2:
Multiple locking shafts and connecting plates are merged into an integrated locking matching structure. The first and second connecting plates connect the locking shafts to the frame body, forming a unified assembly that works together to provide stable locking while maintaining structural compactness.
2Adaptability or versatility
If the locking shaft is freely arranged, then the installation is flexible, but the locking shaft is prone to horizontal offset and disengagement from the locking mechanism
Solution Approach 1:
The first and second connecting plates act as intermediary elements between the locking shaft and the frame body. These connecting plates provide a stable transmission path for locking forces and constrain the locking shaft's position, preventing horizontal offset while allowing proper installation alignment through the plate connections.
3Ease of manufacture
If battery packs are placed only on the outside of vehicle body longitudinal beams, then the installation is simple, but the space utilization is insufficient and the height space for battery swapping is reduced
Solution Approach 1:
The battery pack placement is extended from a single-dimensional arrangement (only outside the longitudinal beams) to a multi-dimensional configuration that includes both outside and between the longitudinal beams. The frame body spans across the longitudinal beams, creating additional placement positions in the vertical and horizontal dimensions, thereby maximizing space utilization while maintaining adequate height clearance for battery swapping operations.
Data Source
AI summary
Disclosed in the present invention are a battery pack tray and an electric vehicle. The battery pack tray comprises a frame body, wherein at least two placing positions which are sequentially arranged at an interval in a horizontal direction, and a locking cooperating structure are formed on the frame body; the locking cooperating structure is arranged between at least one pair of adjacent placing positions; the locking cooperating structure comprises a locking shaft, and a first connecting plate and a second connecting plate which extend in the lengthwise direction of a longitudinal beam of a vehicle body; and two ends of the locking shaft are respectively connected to the first connecting plate and the second connecting plate, and are used for cooperating with a locking mechanism to realize locking.