Modular Battery Carrier Assembly for Flexible EV Pack Capacity
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Solution Overview
Problem
The high manufacturing costs of battery carriers for electric vehicles due to the need for multiple die-casting molds and expensive die-casting machines, which are required to produce battery carriers of varying sizes and high capacity, are not cost-effectively addressed by existing technologies.
Innovation Solution
A battery carrier module made of cast aluminum alloy with interconnected walls and connecting elements that allow multiple modules to be connected in series, enabling the production of battery carriers of different sizes using a single die-casting mold and reducing the need for large, expensive die-casting machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple die-casting molds are used to produce battery carriers of varying sizes, then different vehicle requirements can be met, but manufacturing costs increase due to the need to maintain multiple molds
Solution Approach 1:
The battery carrier is divided into multiple modular sections that can be produced using a single die-casting mold. Each module can be independently manufactured and then assembled to create battery carriers of different sizes and capacities, eliminating the need for multiple specialized molds while maintaining adaptability to different vehicle requirements.
2Strength
If large die-casting machines are used to produce high-capacity battery carriers, then clamping forces of over 4,500 kN can be achieved, but the machines are expensive and drive up manufacturing costs
Solution Approach 1:
High-capacity battery carriers are constructed by assembling multiple smaller modules produced on less expensive die-casting machines. The modular design allows the use of machines with lower clamping forces (under 4,500 kN) while still achieving the required structural strength through proper module configuration and connection, thereby reducing equipment investment costs.
3Adaptability or versatility
If multiple permanent molds are maintained for different battery holder variants, then all vehicle models can be served, but production costs increase due to mold maintenance and complexity
Solution Approach 1:
A single die-casting mold is designed to produce universal battery carrier modules that can be configured to serve different vehicle models. The mold creates standardized modules with universal connection interfaces, allowing the same mold to produce components for various battery carrier sizes and applications, thereby reducing the total number of molds required while maintaining broad vehicle model coverage.
Data Source
Figure 1A~2B
Figure 3A~3E
Figure 4A~4B
AI summary
The invention relates to a battery carrier module (6) for forming a battery carrier (2), in particular made of an aluminum casting alloy, which can be connected to a vehicle body. The battery carrier module comprises: a receiving area (16) for receiving at least one battery module serving as a drive energy storage device for an electrically powered vehicle (36), at least three interconnected walls (8, 10, 12), and a first outer surface and a second outer surface, wherein at least one first connecting element (18) is arranged on the first outer surface and at least one second connecting element (20) corresponding to the first connecting element (18) is arranged on the second outer surface, and wherein the walls (8, 10, 12) and the connecting elements (18, 20) are arranged such that several, preferably identical, battery carrier modules (6) can be connected together in series. The invention also relates to a battery carrier.