Vehicle Energy Store Compensation Apparatus for Crash Load Management
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Solution Overview
Problem
Existing energy stores in vehicles are prone to damage due to relative movement between the housing and energy store cells during high load or acceleration peaks, such as in crash situations, as they lack a mechanism to prevent such movement.
Innovation Solution
An energy store with a compensation apparatus embedded between the housing and energy store cell arrangement, which dampens or suppresses relative movement, and a deformation element to manage load distribution and reduce deformation, enhancing robustness and preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the energy store cells are embedded in the housing with clearances due to manufacturing tolerances, then the ease of manufacture is improved, but the reliability deteriorates due to relative movement during load peaks causing damage to cells or housing
Solution Approach 1:
A compensation apparatus is introduced as an intermediary element between the housing and the energy store cell arrangement. This compensation apparatus absorbs relative movements and deformations during load peaks, preventing direct contact and potential damage between the housing and cells, thus maintaining reliability while preserving manufacturing tolerances
Solution Approach 2:
The compensation apparatus is pre-installed in the clearance between the housing and energy store cells to provide beforehand cushioning. When load peaks occur during operation, the compensation apparatus has already been positioned to absorb shocks and prevent damage, ensuring reliability without compromising manufacturing ease
2Adaptability or versatility
If the energy store cell arrangement is allowed to move relative to the housing during operation, then the adaptability is improved, but the strength deteriorates due to damage to energy store cells or housing deformation under high load
Solution Approach 1:
The compensation apparatus serves as a mediator that allows controlled adaptability through pre-compression while preventing harmful relative movements during load peaks. The apparatus is pre-compressed during assembly and maintains constant contact pressure, enabling the system to adapt to operational conditions without compromising the strength of cells or housing
3Device complexity
If the compensation apparatus is embedded in the clearance between housing and energy store cells, then the device complexity is increased, but the reliability is improved by suppressing relative movement during crash situations
Solution Approach 1:
The compensation apparatus is designed as a simple, replaceable component that can be easily manufactured and installed. Rather than making the entire energy store system more complex, a relatively simple compensation element is introduced that can be replaced if needed, providing high reliability improvement with minimal increase in overall device complexity
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 solution effectively prevents damage to energy store cells and housing during load or acceleration peaks by stabilizing the energy store cell arrangement within the housing, reducing the risk of deformation and enhancing the energy store's robustness.
Implementation Method 1
The compensation apparatus is elastically deformable and may comprise a spring element
Implementation Method 2
The deformation element controls the load distribution between the housing wall, and the energy store cell arrangement to avoid local housing overloading
Implementation Method 3
the deformation element can reduce local and global deformations of the housing in a crash situation
Data Source
AI summary
An energy store for a vehicle has an energy store cell arrangement and a housing that at least partly covers the energy store cell arrangement. A compensation apparatus is arranged between the housing and the energy store cell arrangement.