Heavy-Duty EV Battery Mounting With Vibration Isolation and Sealing
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Solution Overview
Problem
Current electric power systems for larger and heavy-duty vehicles have limitations in modularity, integration, and vibration isolation, which hinder the widespread adoption of electric motors and increase exposure to moisture, affecting performance and reliability.
Innovation Solution
The development of modular electric vehicle systems that include a battery assembly with a housing and mounting system, allowing for improved vibration and shock isolation, and integration with accessory components, enabling flexible configuration and reduced moisture exposure through enhanced sealing and load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If battery assemblies are integrated into vehicle chassis, then mechanical integration and stability are improved, but exposure to moisture and vibration increases
Solution Approach 1:
The battery assembly is divided into separate functional components: the battery housing, mounting system with vibration isolators, and sealing elements. This segmentation allows each component to be optimized independently - the housing for structural integrity, the mounting system for vibration isolation, and the sealing elements for moisture protection.
Solution Approach 2:
Vibration isolators are introduced as intermediary elements between the battery housing and vehicle chassis. These isolators act as mediators that decouple the battery assembly from direct mechanical contact with the chassis, reducing vibration and shock transmission while maintaining secure mounting.
2Reliability
If mounting system is added for battery assembly, then vibration and shock isolation are improved, but device complexity increases
Solution Approach 1:
The mounting system is designed to perform multiple functions simultaneously: mechanical attachment of the battery housing to the chassis, vibration isolation through isolators, and shock absorption. This multi-functionality reduces the need for separate components for each function, thereby managing complexity while improving reliability.
Solution Approach 2:
The mounting system utilizes vibration isolators with specific material properties and geometric configurations that can be adjusted to optimize vibration and shock isolation performance. By changing parameters such as isolator stiffness, damping characteristics, and mounting geometry, the system achieves improved reliability without requiring overly complex structures.
3Ease of manufacture
If modular system is used for battery assembly, then ease of assembly and expansion are improved, but manufacturing precision requirements increase
Solution Approach 1:
The battery assembly is designed as a modular system with distinct segments: the housing, mounting system, sealing elements, and battery units. This segmentation enables independent manufacturing and assembly of each module, simplifying the overall assembly process and allowing for easier expansion by adding or removing modules.
Solution Approach 2:
The housing incorporates flexible sealing elements and gaskets that can accommodate minor variations in manufacturing tolerances. These flexible components maintain effective seals and connections even when precise dimensional control is difficult to achieve, thereby reducing the stringency of manufacturing precision requirements while maintaining assembly ease.
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 modular system enhances the integration of battery assemblies into vehicle chassis, providing improved vibration isolation, reduced moisture exposure, and flexible configuration, thus improving the performance and reliability of electric power systems in larger and heavy-duty vehicles.
Implementation Method 1
The vibration isolator is configured to reduce load transmission from the frame member of the vehicle to the housing
Data Source
AI summary
A battery assembly for an electric vehicle is provided that includes a housing, one or more battery units, and a mounting system. The one or more battery units are disposed within the housing. The mounting system is disposed adjacent to a top surface, e.g., on a planar top surface or within an upwardly oriented concavity. The mounting system has a frame member bracket and a housing bracket system. The housing bracket system includes a housing bracket, a load member and a vibration isolator. The housing bracket is configured to be coupled to the frame member bracket. The load member has a first portion disposed adjacent to an upper surface and a second portion disposed along a lateral portion of the housing. The vibration isolator is disposed between the load member and the housing bracket. The vibration isolator is configured to reduce load transmission from the frame member of the vehicle to the housing.