Hydrogen Tank Superstructure With Gantry Bars for Safer Truck Assembly
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Solution Overview
Problem
The assembly of hydrogen fuel tanks on heavy-duty vehicles is challenging due to the large and heavy nature of the assembly framework, which requires manual handling at elevated heights, increasing the risk of injury and complicating the secure mounting process, while also needing improved safety measures for the hydrogen tanks.
Innovation Solution
A superstructure with laterally oriented gantry bars providing a continuous load-bearing structure across the assembly, allowing for easy lifting and secure mounting onto the vehicle, and incorporating guidable supports for precise alignment and form locking attachments, reducing the need for manual handling at heights and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large and heavy assembly framework is used to securely mount hydrogen tanks, then the mounting security is improved, but the difficulty of assembly and risk of injury to personnel increases due to manual handling at elevated heights
Solution Approach 1:
The assembly framework is divided into a base structure and a superstructure that can be assembled separately. The superstructure containing the hydrogen tanks can be hoisted as a complete unit and then attached to the base structure on the ground, eliminating the need for personnel to work at elevated heights during assembly.
Solution Approach 2:
The superstructure is pre-assembled on the ground with all mounting components in place before being hoisted to the vehicle. This preliminary assembly allows all securement operations to be performed at ground level, improving both safety and ease of operation.
2Object-affected harmful factors
If the superstructure is designed to absorb lateral forces in rollover accidents, then the protection of hydrogen tanks is improved, but the weight and complexity of the structure increases
Solution Approach 1:
The gantry bars are designed to extend beyond the hydrogen tanks laterally, creating an extended protective framework specifically positioned to absorb lateral impact forces during rollover accidents. This localized reinforcement provides protection without requiring the entire structure to be uniformly strengthened.
Solution Approach 2:
The extended gantry bars are positioned in advance to intercept and absorb lateral forces before they can reach the hydrogen tanks. This proactive design allows the structure to cushion the impact before it affects the protected components.
3Object-affected harmful factors
If the gantry bars extend beyond the hydrogen tanks, then the absorption of lateral forces is improved, but the material usage and structural complexity increases
Solution Approach 1:
The gantry bars serve multiple functions: they provide the primary mounting structure for the hydrogen tanks, enable the superstructure to be hoisted as a unit, and extend laterally to absorb rollover forces. This multi-functionality reduces the need for separate protective structures, simplifying the overall design despite the extended geometry.
Data Source
AI summary
A superstructure for carrying hydrogen fuel tank(s) on a heavy-duty vehicle is provided. The superstructure comprises at least one laterally oriented gantry bar that provides a continuous load bearing structure across the superstructure, wherein the at least one laterally oriented gantry bar is arranged to extend beyond carried hydrogen fuel tank(s) in the superstructure. A vehicle comprising the superstructure and a method for assembling a superstructure on a heavy-duty vehicle are also provided.