Modular Vehicle Battery Enclosure for Fast Fleet Servicing
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Solution Overview
Problem
Servicing a large fleet of micro-mobility vehicles, such as electric kick scooters and bicycles, poses significant capital investment and labor burdens due to the need for frequent maintenance and quick operational readiness in dynamic transportation systems.
Innovation Solution
The development of modular battery assemblies with retention interfaces that securely attach to a subframe assembly, allowing for easy replacement and integration of battery cell assemblies with moisture-sealing enclosures and arched floorboard panels, reducing the need for separate structural elements and simplifying maintenance processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional battery assemblies are used in micro-mobility fleet vehicles, then the vehicles can operate, but the labor and capital costs for servicing the fleet increase significantly due to complex maintenance procedures and extended downtime
Solution Approach 1:
The battery assembly is divided into modular components including a battery cell assembly, an enclosure assembly with lid and base, and a floorboard assembly. These segmented modules can be independently serviced, replaced, or repaired without affecting the entire vehicle system, enabling rapid fleet maintenance and reducing vehicle downtime.
Solution Approach 2:
The battery assembly is designed as a universal platform that integrates multiple functions: power storage (battery cells), structural support (floorboard assembly), environmental protection (enclosure with sealing), and rider interface (footrest surface). This multi-functional integration eliminates the need for separate structural elements in the vehicle, simplifying maintenance procedures and reducing servicing time.
2Strength
If separate structural elements are used for the floorboard and battery enclosure, then the vehicle structure can be optimized, but the device complexity and manufacturing costs increase
Solution Approach 1:
The floorboard assembly is merged with the battery enclosure structure. The floorboard serves dual purposes: as a rider interface surface and as a structural component that integrates with the enclosure lid and battery cell holder. This consolidation reduces the number of separate components, simplifies assembly, and maintains structural integrity without increasing device complexity.
3Ease of manufacture
If the battery enclosure is not sealed, then manufacturing is simpler, but moisture ingress damages the battery cells and reduces reliability
Solution Approach 1:
A sealing gasket or seal is introduced between the enclosure lid and base, utilizing flexible material properties to create an effective moisture barrier. This thin film sealing solution protects the battery cells from environmental moisture while maintaining a relatively simple enclosure assembly structure that doesn't require complex sealing mechanisms.
Data Source
AI summary
Techniques are disclosed for systems and methods to provide modular battery assemblies for micro-mobility fleet vehicles. A modular battery assembly for a micro-mobility fleet vehicle includes a battery assembly enclosure including an assembly retention interface configured to physically secure the assembly enclosure to a subframe assembly of the micro-mobility fleet vehicle, a battery cell assembly disposed within the battery assembly enclosure, and an enclosure lid mounted to the assembly enclosure. The modular battery assembly may include an arched floorboard panel configured to provide a floor board surface for the micro-mobility fleet vehicle. The battery cell assembly may include a honeycomb battery cell holder and a collector board atop the battery cell holder to provide wire bond interconnects between the battery cells.