Transverse Battery Mounting for Heavy-Duty Vehicle Service
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Solution Overview
Problem
The assembly and disassembly of energy storage systems, such as batteries, in heavy-duty vehicles are time-consuming due to their heavy weight and conventional placement along longitudinally extending frame rails, necessitating a more efficient and simplified mounting process.
Innovation Solution
An energy storage mounting system that includes vertically spaced-apart first energy storage unit mounting members and inter-connecting members, allowing for the connection of energy storage units to a vehicle's longitudinal frame from a transverse side, with rotational-locking and guide-aligning features to secure and align the units, and elongated inter-connecting members for tensioned interconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batteries are placed along the longitudinally extending frame rails of the vehicle, then the energy storage system can be securely mounted to the vehicle chassis, but the assembly/disassembly process becomes time-consuming due to the heavy weight of the batteries
Solution Approach 1:
The mounting system is divided into separate components: mounting members attached to the frame rails, connecting portions on the battery units, and inter-connecting members that join batteries together. This segmentation allows for modular assembly where batteries can be connected to each other independently before being mounted to the frame, reducing overall assembly time while maintaining secure mounting.
Solution Approach 2:
The connecting portion acts as an intermediary element between the battery unit and the mounting member. It provides a standardized interface that simplifies the connection process, allowing heavy batteries to be quickly attached to the frame rails through a straightforward coupling mechanism rather than complex fastening procedures.
2Strength
If conventional mounting methods are used for heavy batteries, then the batteries can be firmly attached to the vehicle chassis, but the assembly/disassembly process becomes complex and time-consuming
Solution Approach 1:
The mounting system separates the attachment function into distinct components: mounting members on the frame, connecting portions on batteries, and inter-connecting members. This segmentation simplifies each individual component's design, allowing for strong attachments without requiring complex overall systems. Each segment can be optimized independently for its specific function.
Solution Approach 2:
The system combines multiple functions into integrated components. The connecting portion serves both as a mounting interface and an interconnection element, while the inter-connecting members simultaneously attach batteries to the frame and secure them together. This merging reduces the number of separate parts and simplifies the assembly process while maintaining strong attachments.
3Stability of the object's composition
If energy storage units are connected to the vehicle frame, then they are securely positioned, but they become subject to vehicle frame motion which can lead to forces and loads on the battery packs
Solution Approach 1:
The energy storage units are extracted from direct rigid connection to the vehicle frame. Instead of being firmly bolted to the frame, the batteries are suspended from the mounting members, which allow controlled movement. This extraction isolates the batteries from frame motion while maintaining positional stability, preventing transmission of forces and loads to the battery packs during vehicle operation.
Solution Approach 2:
The connection characteristics between the battery packs and vehicle frame are changed from rigid to flexible/suspended. This parameter change allows the system to maintain position stability while accommodating frame motion without transmitting harmful forces to the batteries. The suspension arrangement provides the necessary compliance to decouple the batteries from frame dynamics.
Data Source
Figure 1a
Figure 1b
Figure 2a
AI summary
27 ABSTRACT The present disclosure relates to an energy storage mounting system (100) for an energy storage system, ESS, (20) of a vehicle (1), extending in a longitudinal direction (X), a transverse direction (Y) and in a vertical direction (Z), the energy storage mounting system comprising vertically spaced-apart first energy storage unit 5 mounting member (40) and energy storage units inter-connecting member (50), wherein the first energy storage unit mounting member (40) is connectable to a first energy storage unit (80) of the ESS (20), the energy storage unit mounting member (40) comprising a connecting portion (42) configured to connect with a vehicle mounting member (30); and the energy storage units inter-connecting member (50, 10 50') is connectable to the first energy storage unit (80) of the ESS (20) and configured to transversely inter-connect the first energy storage unit with a transversely opposite second energy storage unit (80'). 15 For publication: Fig. 1b