Pivoting EV Battery Mount for Torsionally Flexible Chassis
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Solution Overview
Problem
Commercial truck chassis become too rigid and stiff when battery packs are rigidly mounted, compromising their torsional flexibility, which is essential for durability.
Innovation Solution
A semi-isolated electric vehicle battery mount system that uses a pivot bracket and pivot pin to allow torsional rotation of the battery pack, enabling the chassis to remain flexible while securely mounting rigid battery packs between frame rails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If battery packs are rigidly mounted to the frame rails, then the battery packs are securely fixed, but the chassis becomes too rigid and loses torsional flexibility
Solution Approach 1:
The mounting system transitions from a static rigid connection to a dynamic articulated connection using pivot brackets and pivot pins. The battery pack mounting bracket is connected to the chassis frame rail through a pivot pin that allows rotational movement, enabling the chassis to flex in torsion while keeping the battery securely mounted. This dynamic connection resolves the contradiction by allowing both secure mounting and chassis flexibility.
Solution Approach 2:
A pivot bracket serves as an intermediary element between the battery pack mounting bracket and the chassis frame rail. This intermediary component absorbs the torsional stresses through its pivot connection, allowing the battery to remain securely mounted while the chassis maintains its natural flexibility. The pivot bracket mediates between the rigid battery pack and the flexible chassis structure.
2Reliability
If battery packs are mounted between the frame rails, then the batteries are better protected, but the frame becomes too rigid and stiff
Solution Approach 1:
The mounting system uses dynamic pivot connections instead of rigid fixed mounts. The pivot pin allows the battery mounting bracket to rotate relative to the frame rail, enabling the frame to flex in torsion even when batteries are mounted between the rails. This maintains both battery protection through positioning and chassis flexibility through the pivot mechanism.
Solution Approach 2:
The system changes the degree of freedom parameter of the battery mounting from fixed (zero degrees of freedom) to articulated (one degree of freedom for rotation). This parameter change allows the mounting system to provide both secure battery positioning for protection and accommodate frame torsional movements, resolving the contradiction between protection and flexibility.
Data Source
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.