Pivoting EV Battery Mount for Torsionally Flexible Chassis
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Solution Overview
Problem
Electric vehicle battery packs rigidly mounted to truck chassis make the frame overly rigid and stiff, compromising its torsional flexibility, which is necessary for durability.
Innovation Solution
A semi-isolated battery mount system using a pivot bracket and pivot pin allows the battery pack to pivot between frame rails, maintaining chassis flexibility while securing the battery pack, thereby allowing torsional rotation along the longitudinal axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery packs are rigidly mounted to the frame rails, then the battery packs are securely fixed and protected, but the chassis becomes overly rigid and loses torsional flexibility
Solution Approach 1:
The mounting system transitions from a static rigid connection to a dynamic semi-rigid connection using spring elements. The springs allow the battery pack to be securely held in position while permitting controlled movement and deformation of the chassis frame during torsional flexing, thus maintaining both security and flexibility.
Solution Approach 2:
The mounting system combines rigid components (mounting brackets, attachment points) with flexible elements (springs). This composite approach creates a hybrid mounting structure that provides both the structural support needed for secure battery fixation and the compliance necessary to preserve chassis torsional flexibility.
2Object-affected harmful factors
If battery packs are rigidly mounted between frame rails, then protection is improved, but the frame stiffness increases excessively
Solution Approach 1:
The spring-based mounting system introduces dynamic compliance between the battery pack and frame rails. The springs provide protective support while allowing the frame to flex during torsional loads, preventing excessive stiffness buildup while maintaining adequate protection.
Solution Approach 2:
The mounting system changes the mechanical parameters of the connection from rigid (high stiffness) to semi-rigid (controlled stiffness through spring rate). By selecting appropriate spring characteristics, the system achieves optimal balance between protection and frame flexibility.
Data Source
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AI summary
The present system as disclosed herein provides for a battery mount system configured to position batteries below an upper plane of a cross member of an electric vehicle chassis. The system of the present application provides a semi-isolated electric vehicle battery mount for a torsionally flexible chassis. The system includes a bracket configured to enable the batteries to be positioned below and between the cross members of the chassis. The bracket generally includes battery hangers and corresponding mounts, a pivot, a pivot pin, a pivot bracket all mounted to the cross member enabling the batteries to rest below an upper plane of the cross member and pivotable with respect to the cross member.