Central Vehicle Frame Layout for Large Battery Packaging
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Solution Overview
Problem
Conventional frame structures in heavy-duty vehicles are not dimensioned to accommodate large batteries, limiting the vehicle's range and requiring inefficient battery placement.
Innovation Solution
A frame structure with a load-bearing frame arrangement positioned at the transversal center of the vehicle, featuring diagonal extensions that increase stiffness and allow for larger battery placement, along with brackets for additional support and component routing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional longitudinally extending frame rails are used for battery placement, then the frame structure is simple and easy to manufacture, but the available space for batteries is insufficient and the frame cannot support sufficiently large batteries
Solution Approach 1:
The patent transitions from conventional longitudinal battery placement along frame rails to a transverse arrangement where batteries are positioned on either side of a central load-bearing frame arrangement. This dimensional change in battery orientation and positioning creates additional space, enabling larger battery capacity while maintaining frame structure simplicity.
2Strength
If the load bearing frame arrangement is positioned at the transversal center portion with diagonal extensions, then the stiffness and load-bearing capacity are improved, but the device complexity increases
Solution Approach 1:
The load-bearing frame arrangement employs asymmetric diagonal extensions that slope downward from the central connection point toward the front and rear suspension arrangements. This asymmetric geometric configuration optimizes structural stiffness and load distribution while maintaining manufacturing feasibility through standardized diagonal member components.
Solution Approach 2:
The diagonal extensions are pre-configured with integrated channels during frame manufacturing, allowing routing highways and power electronic components to be pre-positioned within these channels before final assembly. This preliminary structuring reduces on-site assembly complexity and ensures proper component integration.
3Quantity of substance
If larger batteries are arranged on each side of the load bearing frame arrangement, then the driving range is extended, but the available space and routing for components becomes more constrained
Solution Approach 1:
The diagonal extensions of the load-bearing frame arrangement serve multiple functions simultaneously: they provide structural stiffness and load-bearing capacity, create defined channels for routing highways and power electronic components, and establish a standardized framework that accommodates various component configurations. This multi-functionality enables larger battery capacity while managing routing complexity through the universal diagonal member design.
Data Source
AI summary
The present disclosure relates to a frame structure for a vehicle comprising a front wheel suspension arrangement for suspending a pair of front wheels of the vehicle and a rear wheel suspension arrangement for suspending a pair of rear wheels of the vehicle, wherein the frame structure comprises a load bearing frame arrangement arranged to be positioned at a transversal center portion of the vehicle, the load bearing frame arrangement comprising a first member and a second member, each of the first and second members forming a diagonal extension as seen in a transversal cross section of the load bearing frame arrangement, wherein the diagonal first and second members extend longitudinally between the front wheel suspension arrangement and the rear wheel suspension arrangement, wherein the diagonal extension of the first member interconnects with the diagonal extension of the second member forming a connection point between the first and second members.