Skateboard Chassis Battery Layout for Electric Heavy-Duty Vehicles
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Solution Overview
Problem
The integration of a large battery pack into heavy-duty vehicles for electric propulsion poses packaging constraints, requiring modifications to vehicle configuration, including the adoption of front-wheel drive and reconfiguration of electrical sub-systems, while also necessitating efficient integration and removal of the battery pack without compromising the vehicle's structural integrity.
Innovation Solution
The implementation of a skateboard chassis with an integrated battery pack, coupled with front-wheel drive utilizing drive shaft adapters that enable regenerative braking, and a cradle for consolidating electrical sub-systems, addresses the packaging constraints and enhances the vehicle's efficiency and maintainability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a large battery pack is installed in the vehicle chassis to provide electric propulsion, then the vehicle can achieve zero emissions and reduced operating costs, but the battery pack occupies significant space and creates packaging constraints that require modifications to vehicle configuration
Solution Approach 1:
The vehicle is divided into modular sections: a skateboard chassis containing the battery pack, a separate cab, and independently mounted electrical sub-systems on a cradle. This segmentation allows the battery pack to be positioned low in the chassis without interfering with other components, resolving the packaging constraint while maintaining the electric propulsion benefit
Solution Approach 2:
The battery pack is positioned in the vertical dimension (low in the chassis) rather than occupying horizontal space. This vertical placement strategy allows the large battery pack to be integrated without increasing the vehicle's footprint, enabling zero emissions while maintaining packaging efficiency
2Area of stationary object
If the vehicle is reconfigured with front-wheel drive to accommodate the battery pack positioning, then space is freed up along the chassis underside, but the drive train configuration becomes more complex and requires drive shaft adapters
Solution Approach 1:
The hub assemblies are designed as universal components that can accommodate both drive shaft connections and regenerative braking functions. The drive shaft adapters provide a standardized interface that works with the front-wheel drive configuration, reducing the overall complexity despite the non-conventional layout
Solution Approach 2:
Drive shaft adapters serve as intermediary components that connect the motor to the front wheels. These adapters simplify the connection interface and enable the front-wheel drive configuration to work efficiently with the battery pack positioned low in the chassis, freeing up space along the chassis underside
3Ease of operation
If electrical sub-systems are distributed throughout the vehicle, then each sub-system can be positioned near its functional location, but the overall footprint of electrical sub-systems increases and assembly time increases
Solution Approach 1:
Multiple electrical sub-systems (hydraulic pump, air compressor, air conditioning compressor, wiring harnesses, brake lines) are merged and consolidated onto a single cradle structure. This consolidation reduces the total footprint of electrical sub-systems from being distributed throughout the vehicle to a compact centralized location, while still allowing each sub-system to be positioned near its functional location through the cradle's strategic placement
4Strength
If the battery pack is permanently integrated into the chassis, then the vehicle structure is strengthened, but the battery pack cannot be readily removed for maintenance or replacement
Solution Approach 1:
The battery pack integration is made dynamic rather than static. The skateboard chassis design allows the battery pack to be securely integrated for structural strength during operation, while the modular connection interfaces enable easy removal and reinstallation. This dynamic approach balances structural integrity with maintenance accessibility
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration allows for efficient packaging of sub-system power electronics, reduces assembly time, and enables regenerative braking, thereby enhancing the vehicle's power efficiency and reducing costs associated with custom components.
Implementation Method 1
a battery pack for supplying current to an electric motor of the vehicle
Implementation Method 2
the drive shaft adapters are configured to permanently couple the hub assemblies to drive shafts of the front wheels, wherein the front wheels are adapted with regenerative braking
Data Source
AI summary
Methods and systems are provided for an electric heavy-duty vehicle. In one example, the vehicle includes a battery pack for supplying current to an electric motor of the vehicle, the battery pack arranged in a chassis of the vehicle and configured to form part of a floor of the vehicle. The vehicle also includes a motor coupled to front wheels of the vehicle, the front wheels having hub assemblies housing drive shaft adapters configured to permanently couple the hub assemblies to drive shafts of the front wheels, and a cradle configured to be mounted with electrical sub-systems of the vehicle.