EV Battery Module Layout With Rail-Mounted Structural Packs
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Solution Overview
Problem
Electric vehicles face challenges in providing sufficient battery power for long distances and powering multiple components due to limitations in battery technology.
Innovation Solution
A battery power system for electric vehicles comprising a frame with rails, a container mounted to the rails, and battery packs extending across the container's length, protected by a lightweight container and connected via a power distribution unit (PDU), which enhances structural strength and protects against debris and moisture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If battery packs are extended across the entire length of the container, then structural strength and torsional rigidity are improved, but device complexity increases
Solution Approach 1:
The battery packs are designed to extend across the entire length of the container, merging the structural support function with the power storage function. This integration allows the battery packs to serve dual purposes: providing electrical power while simultaneously reinforcing the vehicle's frame and improving torsional rigidity, thereby reducing the need for separate structural components.
Solution Approach 2:
The battery packs are configured to perform multiple functions: they provide electrical power to vehicle components and simultaneously act as structural reinforcement elements. By making the battery packs multi-functional, the design eliminates the need for additional dedicated structural components, thus improving strength without proportionally increasing device complexity.
2Reliability
If a container is added to protect battery packs from road debris and moisture, then reliability is improved, but weight increases
Solution Approach 1:
A container is introduced to enclose and protect the battery packs from road debris, moisture, and other environmental hazards. The container acts as a protective shell, ensuring the battery packs operate in a controlled environment, which improves reliability by preventing damage from external factors.
3Power
If multiple battery packs are positioned within the container, then power capacity is improved, but volume occupied increases
Solution Approach 1:
The battery system is divided into multiple individual battery packs rather than using a single large battery unit. Each battery pack can be independently positioned within the container, allowing for optimized spatial arrangement. This segmentation enables the system to achieve higher total power capacity while efficiently utilizing the available volume within the container.
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. The system may comprise a container configured to be mounted to the one or more rails. The system may comprise a plurality of battery packs positioned within the container below the one or more rails. Each of the plurality of battery packs may extend across an entire length of the container. The system may comprise a power distribution unit (PDU) to which the plurality of battery packs are connected. The plurality of battery packs may be configured to provide power to at least one component of the vehicle via the PDU. The container may protect against road debris and moisture.