Refuse Vehicle Battery Pack Layout for Weight Balance and Hot-Swap Access
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Solution Overview
Problem
Existing refuse vehicles face challenges in efficiently powering operations without combustion engines, managing battery weight distribution, and facilitating easy access and maintenance of energy storage systems.
Innovation Solution
The integration of a detachable and modular energy storage and generation system positioned strategically on the refuse vehicle to evenly distribute weight, enhance accessibility, and allow for hot-swapping and easy maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are integrated into the refuse vehicle body, then the vehicle can be fully powered by battery cells without combustion engine, but the weight distribution and accessibility for maintenance become challenging
Solution Approach 1:
The battery system is divided into multiple individual battery cells that can be independently accessed and replaced. Each battery cell is positioned in a separate location within the body assembly, allowing operators to service individual cells without shutting down the entire system or disassembling large portions of the vehicle structure.
Solution Approach 2:
A removable tray or mounting structure serves as an intermediary between the battery cells and the vehicle chassis. This intermediary component allows for easy insertion and removal of battery cells, facilitating maintenance while maintaining secure electrical and mechanical connections during operation.
2Weight of moving object
If battery cells are positioned within the body assembly, then weight can be distributed, but access for hot-swapping and maintenance becomes difficult
Solution Approach 1:
The body assembly is segmented into multiple access points and compartments, each providing access to specific battery cells. This segmentation allows maintenance personnel to reach individual cells without disassembling the entire body structure, while still achieving proper weight distribution through strategic placement of cells throughout the assembly.
Solution Approach 2:
The body assembly structure is designed to serve multiple functions: it provides structural support for weight distribution, creates protected housing for battery cells, and incorporates universal access mechanisms such as removable panels or doors that facilitate maintenance of any cell from external locations.
3Ease of repair
If battery cells are replaceable and detachably coupled, then maintenance and upgrades become easier, but system complexity increases
Solution Approach 1:
The electrical connections and mounting features are extracted as standardized interfaces between the battery cells and the vehicle system. These extracted interfaces include removable electrical connectors and mechanical mounting points that simplify the coupling process, reducing complexity while maintaining replaceability and upgrade capabilities.
Data Source
AI summary
A vehicle includes a chassis, a front axle coupled to the chassis, a rear axle coupled to the chassis, and an electric energy system. The electric energy system includes a first battery pack positioned forward of the rear axle and supported by the chassis and a second battery pack positioned separate from the first battery pack rearward of the rear axle. An uppermost periphery of the first battery pack is spaced a distance below a top of the chassis and above a bottom of the chassis. At least a portion of the first battery pack extends lower than the bottom of the chassis. At least a portion of the second battery pack is positioned at an elevated height relative to the first battery pack such that an uppermost periphery of the second battery pack is positioned above a point at which a body assembly contacts the top of the chassis.