Modular Battery Pack Layout for Refuse Vehicle Hot-Swapping
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Solution Overview
Problem
Existing refuse vehicles face challenges with battery systems that are not easily accessible, removable, or modular, leading to high maintenance costs, downtime, and limited flexibility in charging and upgrading.
Innovation Solution
A detachable and modular energy storage and generation system for refuse vehicles, positioned to distribute weight evenly, facilitate easy access, and allow hot-swapping of battery cells, enabling faster charging and component upgrades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are permanently integrated into the vehicle body, then structural stability is improved, but maintenance cost and downtime increase
Solution Approach 1:
The battery system is divided into modular battery cell assemblies that can be independently removed and replaced. Each battery cell assembly is a discrete unit that can be detached from the vehicle body without affecting the overall structural integrity, enabling quick replacement during maintenance while preserving structural stability during normal operation.
Solution Approach 2:
The battery cell assemblies are designed with dynamic coupling mechanisms that allow them to be securely attached during operation for structural stability, but easily detached when maintenance is needed. The coupling system transitions between a locked stable state during operation and an unlocked removable state during maintenance.
2Reliability
If battery cells are fixed in position, then structural stability is improved, but accessibility and flexibility for charging/upgrading worsen
Solution Approach 1:
The battery system is segmented into individual replaceable battery cell assemblies that can be accessed independently. Each assembly can be removed through accessible access points in the vehicle body, allowing operators to charge or upgrade specific battery cells without disassembling the entire vehicle structure.
Solution Approach 2:
Battery cell assemblies are designed to be extractable from the vehicle body through designated access points. The extraction mechanism allows complete removal of battery cell assemblies from the vehicle for external charging or upgrading, while maintaining structural stability when installed.
3Stability of the object's composition
If battery system is integrated into vehicle body, then weight distribution is improved, but modularity and ease of replacement worsen
Solution Approach 1:
The battery system is divided into standardized modular assemblies that maintain consistent weight and dimensions. These segmented modules can be arranged in different configurations to achieve proper weight distribution, and each module can be independently replaced without affecting the overall weight balance when proper replacement procedures are followed.
Solution Approach 2:
The battery cell assemblies are designed as universal modules that can be used in multiple positions and configurations within the vehicle. The standardized interface and mounting system allow the same module to serve multiple functions and maintain weight distribution requirements across different installation scenarios.
Data Source
AI summary
An electrified vehicle includes a chassis, a cab coupled to the chassis, a body assembly coupled to the chassis, and an energy storage system. The body assembly is positioned behind the cab with a space defined therebetween. The energy storage system is positioned within the space between the cab and the body assembly. The energy storage system includes a housing and a plurality of battery cells disposed within the housing. The housing is coupled directly to the chassis and extends upward from the chassis such that a portion of the housing is positioned above at least a portion of a roof of the cab.