Modular Battery Support Structure for Lightweight Public Transport Vehicles
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Solution Overview
Problem
Existing public transport vehicles face challenges with heavy and complex supporting racks for electric batteries, which increase weight, cost, and complexity in assembly and replacement, and lack versatility in accommodating batteries of different sizes and positions.
Innovation Solution
A modular support structure with rigid, metallic components is used to secure electric battery modules to the vehicle body, allowing easy installation and adaptation to different sizes and positions without elastic bushings, using a three-level assembly system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex supporting racks with many metal plates and elastic bushings are used to support electric batteries, then the batteries can be securely fixed and accommodated with cables and cooling tubes, but the weight of the vehicle increases significantly
Solution Approach 1:
The support structure is divided into a modular rack system comprising multiple separate metal plates that can be independently positioned and assembled. This segmentation allows each plate to be optimized for specific functions (battery support, cable routing, cooling tube accommodation) while reducing overall material usage compared to a monolithic structure.
Solution Approach 2:
The metal plates are designed to perform multiple functions simultaneously: supporting battery modules, routing electric cables, accommodating cooling tubes, and providing structural attachment points. This multi-functionality eliminates the need for separate components for each function, reducing total weight while maintaining reliability.
2Reliability
If complex supporting racks with many welded metal plates are used, then the batteries can be securely supported, but the assembly and replacement processes become time-consuming and complex
Solution Approach 1:
The rack is composed of discrete metal plate modules that can be pre-assembled and then quickly connected using standardized fastening mechanisms, eliminating time-consuming on-site welding operations and enabling rapid battery replacement.
Solution Approach 2:
The metal plates and supporting structures are pre-configured with appropriate openings, mounting points, and routing channels during manufacturing, so that during assembly and replacement, no additional customization or complex fitting is required, significantly reducing installation time.
3Device complexity
If fixed-size supporting racks are used, then the structure can be simplified, but it cannot accommodate batteries of different sizes or positions
Solution Approach 1:
The support structure consists of multiple standardized metal plate modules that can be selectively combined in different configurations. This modular approach maintains structural simplicity through standardization while enabling adaptability through flexible arrangement of modules to accommodate various battery sizes and positions.
Solution Approach 2:
The rack design incorporates adjustable and reconfigurable elements, allowing the support structure to be dynamically adapted to different battery configurations. Metal plates can be repositioned or reconfigured to match various battery module dimensions and mounting requirements.
4Reliability
If elastic bushings and multiple mechanical components are used to fix batteries, then the batteries can be securely mounted, but the overall cost of the vehicle increases
Solution Approach 1:
The functions of elastic bushings, mounting brackets, and securing mechanisms are merged into an integrated metal plate design where the plates themselves provide both structural support and mounting capabilities through built-in attachment points and fastening features, eliminating the need for separate expensive mechanical components.
Solution Approach 2:
The design employs standardized, easily replaceable metal plate components that can be manufactured at low cost using conventional fabrication processes. If damage or wear occurs, individual plates can be replaced independently rather than replacing complex assemblies of multiple precision mechanical parts.
Data Source
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AI summary
A vehicle (1) for public transport comprising a body (2), which is movable on the ground by means of ground engaging wheels (3), extends along a longitudinal axis (A) and is provided with a plurality of walls (5), a floor and a roof (6) delimiting an interior space adapted to accommodate passengers, at least one electric motor configured to provide torque to the ground engaging wheels (3), at least one electric battery module (7) carried by the body (2) and electrically connected to the electric motor, and a support structure (15), which is fixed to the body (2) and is configured to carry the electric battery module (7); the support structure (15) comprises a pair of transversal members (19), which extends transversally to the longitudinal axis (A), are fixed to the body (2) and supports the electric battery module (7); the electric battery module (7) being fixed directly to the transversal members (19) in a removable manner by means of rigid fixing means (20).