EV Battery Box Installation via Insertion Bolt and Spring Mechanism
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Solution Overview
Problem
Existing installation methods for lithium battery boxes in electric vehicles are inconvenient due to high dead weight and limited accessibility, affecting both the aesthetic appeal and practicality of the vehicle, especially when the cross beam is designed to be low or high.
Innovation Solution
An installation structure featuring a battery box with an upper and lower cover, end covers, and sidewalls, an insertion hole, and a vehicle frame oblique beam with an arc-shaped limit groove and U-shaped spring sheets, allowing for secure embedding and easy detachment through an insertion bolt and spring-assisted mechanism, along with a hollow wiring cavity and electric quantity display for real-time monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the cross beam is designed to be low to enhance aesthetic property, then the aesthetic property of the whole vehicle is improved, but it becomes more inconvenient to take out the battery box due to limited space
Solution Approach 1:
The battery box is divided into separable components (battery module and box structure) that can be independently removed. The insertion bolt mechanism allows the battery box to be segmented into removable parts that can be accessed even when the cross beam is low, resolving the conflict between aesthetic design and operational convenience.
Solution Approach 2:
The insertion bolt acts as an intermediary mechanism that enables easy removal of the battery box without requiring significant lifting space. This intermediary device mediates between the low cross beam design (aesthetic requirement) and the need for convenient battery box removal (operational requirement).
2Ease of operation
If the cross beam is designed to be high to facilitate battery box removal, then the convenience of battery box taking-out is improved, but the aesthetic property of the whole vehicle deteriorates
Solution Approach 1:
The battery box removal mechanism is segmented into discrete components (insertion bolt, insertion hole, limit groove) that enable easy removal without requiring high cross beam placement. This segmentation allows the cross beam to be designed low for aesthetics while maintaining operational convenience through the specialized removal mechanism.
Solution Approach 2:
The insertion bolt mechanism serves as an intermediary that facilitates battery box removal without requiring the cross beam to be positioned high. This intermediary mechanism resolves the conflict by enabling convenient removal while allowing the cross beam to be designed low for aesthetic purposes.
3Stability of the object's composition
If the battery box is completely embedded in the installation groove to enhance stability, then the stability of the vehicle frame is improved, but the movement range during installation and taking-out is reduced
Solution Approach 1:
The limit groove and limit bulge are pre-configured to guide the battery box into the correct position during installation. This preliminary action ensures stable embedding while maintaining ease of installation, as the limit structures pre-establish the proper placement without requiring complex adjustment movements.
Solution Approach 2:
The insertion bolt acts as an intermediary mechanism that enables stable embedding of the battery box while facilitating easy installation and removal. The bolt mechanism mediates between the need for stable fixation (complete embedding) and the need for convenient installation/removal operations.
4Ease of operation
If the insertion bolt mechanism is used for locking and fixation, then the ease of installation and detachment is improved, but the device complexity increases due to additional components
Solution Approach 1:
The fixation mechanism is segmented into simple, discrete components (insertion bolt, insertion hole, limit groove, limit bulge) that are easy to manufacture and assemble. This segmentation enables easy installation and detachment while keeping the overall device complexity manageable through the use of simple, standardized parts.
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
Facilitates convenient installation and removal of the battery box, enhances vehicle frame design, improves aesthetics, and enables real-time battery monitoring, ensuring efficient use and performance.
Implementation Method 1
U-shaped spring sheets, allowing for secure embedding and easy detachment through an insertion bolt and spring-assisted mechanism
Data Source
AI summary
The installation structure for the lithium battery box of the electric vehicle includes a battery box body and a vehicle frame oblique beam, where an insertion hole is produced in a front end of the battery box body; an installation groove is produced in the vehicle frame oblique beam; a front battery box base is installed in a front installation groove; an insertion bolt driven through a key is arranged on the front battery box base; where an upwards-bulged arc-shaped limit groove is produced in the middle of the lower cover in the axis of the box body; the installation groove of the vehicle frame oblique beam is an installation groove with a front opening and a rear opening; a limit bulge adaptive to the arc-shaped limit groove is produced on a groove bottom of the installation groove.