EV Battery Module Container With Integrated PDU and Chassis Rigidity
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Solution Overview
Problem
Electric vehicles face challenges in providing sufficient battery power for their components and long-distance driving due to the limitations of existing battery technologies.
Innovation Solution
The development of an electric vehicle battery module system that includes a container mounted to frame rails, housing multiple battery assemblies connected to a power distribution unit (PDU), which can be integrated into existing vehicle chassis without redesign, providing structural rigidity and efficient power distribution to vehicle components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If battery capacity is increased to power large quantities of components and extend driving distances, then the energy storage capability is improved, but the weight and volume of the battery system increase
Solution Approach 1:
The battery system is divided into multiple battery assemblies (first, second, third, and fourth battery assemblies) arranged in a modular configuration. Each assembly can be independently managed and connected to the PDU, allowing flexible scaling of capacity without proportionally increasing overall system weight through optimized structural support distribution.
Solution Approach 2:
The container structure serves multiple functions: it houses the battery assemblies, provides structural support for the vehicle, and integrates with the chassis frame rails. The PDU simultaneously manages power distribution to multiple vehicle components and enables selective operation of battery assemblies, optimizing weight utilization while maintaining high power capacity.
2Use of energy by moving object
If multiple battery assemblies are added to provide sufficient power, then the energy storage is improved, but the device complexity increases
Solution Approach 1:
The power distribution unit (PDU) is designed as a universal power management system that can simultaneously connect to and control multiple battery assemblies (first, second, third, and fourth assemblies). It enables selective operation of individual assemblies based on power requirements, simplifying the control architecture compared to having separate management systems for each assembly.
Solution Approach 2:
Multiple battery assemblies are electrically connected to a single PDU, merging their output into a unified power distribution system. This consolidation reduces the number of separate control units and wiring harnesses needed, thereby reducing overall system complexity while maintaining the ability to draw power from multiple assemblies.
3Power
If a dedicated power distribution system is designed for each battery configuration, then the power distribution capability is improved, but the manufacturing cost increases
Solution Approach 1:
The power distribution unit (PDU) is designed as a universal platform that can accommodate different configurations and numbers of battery assemblies. The same PDU design can manage power from two, three, or four assemblies by simply changing the connection configuration, eliminating the need to design and manufacture different PDU variants for different battery setups, thereby reducing manufacturing costs.
Solution Approach 2:
The battery system is divided into standardized battery assemblies that can be independently manufactured and then configured in different numbers and arrangements. This segmentation allows the manufacturing process to produce uniform, cost-effective assembly units that can be scaled without requiring custom power distribution systems for each configuration.
Data Source
AI summary
A system may comprise a vehicle having a frame. One or more rails may form at least a portion of the frame and the container is configured to provide torsional rigidity to the chassis. The system may comprise a container configured to be mounted to the one or more rails. A plurality of battery assemblies may be enclosed within the container. The system may comprise a power distribution unit (PDU) to which the plurality of battery assemblies are connected. The plurality of battery assemblies may be configured to provide power to at least one component of the vehicle via the PDU.