Modular Battery Pod Layout for Refuse Vehicle Chassis Access
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Solution Overview
Problem
Refuse vehicles face challenges in efficiently managing mechanical, thermal, and physical stresses on battery systems, as well as maintaining accessibility and upgradability of battery components during operation.
Innovation Solution
The integration of a modular battery pod assembly within refuse vehicles, positioned between chassis and body frame rails, featuring stress mitigation devices, thermal management systems, and modular design for easy maintenance and upgrade, including various configurations for optimal placement and weight distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If battery cells are integrated into the chassis frame structure, then mechanical strength and structural stability are improved, but accessibility for maintenance and replacement deteriorates
Solution Approach 1:
The battery system is divided into modular battery cell assemblies that can be independently accessed and replaced. Each battery cell assembly is a discrete unit that can be removed from the chassis frame without requiring disassembly of the entire frame structure, thereby maintaining structural strength while enabling easy maintenance access.
Solution Approach 2:
Access panels or removable covers are introduced as intermediary elements between the battery cells and the external environment. These panels allow maintenance personnel to access battery cells for inspection, maintenance, and replacement without compromising the structural integrity of the chassis frame when closed.
2Stability of the object's composition
If battery cells are positioned to optimize weight distribution, then vehicle stability is improved, but thermal management effectiveness deteriorates
Solution Approach 1:
Different regions of the battery system are designed with different thermal management characteristics. Battery cells positioned in areas with better heat dissipation are assigned higher power density functions, while cells in more constrained thermal environments are optimized for different operational parameters. This allows weight distribution optimization while maintaining adequate thermal management through localized adaptations.
Solution Approach 2:
The thermal management system is nested within the existing chassis structure, utilizing available space between frame members and other components. Cooling channels and thermal management elements are integrated into the structural framework, allowing effective heat dissipation without requiring additional space that would compromise weight distribution and vehicle stability.
3Quantity of substance
If battery cells are arranged to maximize energy density, then energy capacity is improved, but ease of manufacture and assembly deteriorates
Solution Approach 1:
The high-capacity battery system is divided into multiple modular assemblies, each containing a specific number of battery cells arranged in standardized configurations. These modular assemblies can be manufactured independently using standardized processes, then assembled into the complete battery system in the chassis, thereby achieving high energy density while maintaining ease of manufacture and assembly.
Solution Approach 2:
Standardized battery cell assemblies are designed to be universally applicable across different vehicle configurations and positions. The same modular assembly can be installed in various locations within the chassis frame, allowing flexible arrangement to maximize energy density while using standardized manufacturing and assembly procedures.
Data Source
AI summary
A refuse vehicle includes a chassis, a body, and a plurality of battery cells. The chassis includes a right frame member and a left frame member spaced apart in a lateral direction and extending lengthwise in a longitudinal direction. The body is coupled to the chassis. The plurality of battery cells are longitudinally disposed along the chassis, positioned between the right frame member and the left frame member.