Undermounted Structural Battery Box for Refuse Vehicle Packaging
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Solution Overview
Problem
Existing vehicles, particularly vocational vehicles, face challenges in efficiently integrating and supporting battery systems due to space constraints and weight distribution issues, which complicates installation, maintenance, and reduces functionality.
Innovation Solution
A structural battery box is integrated into the chassis, extending beneath the vehicle's axles, providing support, storage, and simplifying battery installation and maintenance while improving weight distribution and functionality by eliminating redundant structures and allowing for a swappable battery module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If batteries are integrated into the vehicle body structure, then weight distribution and space utilization are improved, but installation and maintenance complexity increases
Solution Approach 1:
The battery system is divided into modular battery packs that can be independently installed and removed. Each battery pack is a self-contained unit with standardized interfaces, allowing technicians to service individual packs without disassembling the entire battery system or vehicle structure.
Solution Approach 2:
The battery packs are designed with universal mounting interfaces and standardized electrical connections that work across different vehicle configurations. This multi-functional design allows the same battery pack design to be used in various vehicle types while maintaining ease of installation and maintenance.
2Strength
If a structural battery box is used, then structural support and space optimization are achieved, but device complexity increases
Solution Approach 1:
The battery box is merged with the vehicle's structural frame members, combining the structural support function with the battery containment function into a single integrated component. This eliminates the need for separate structural frames and battery enclosures, reducing overall system complexity.
Solution Approach 2:
The structural battery box serves multiple functions simultaneously: it provides structural support for the vehicle body, contains and protects the battery packs, and serves as a mounting structure for electrical connections. This multi-functionality reduces the number of separate components needed.
3Weight of moving object
If batteries are positioned under the axles, then weight distribution is improved, but accessibility for maintenance deteriorates
Solution Approach 1:
The battery system is segmented into removable packs positioned under the axles for optimal weight distribution. Each pack can be independently accessed and removed through service ports or openings in the vehicle body, maintaining accessibility despite the under-axle positioning.
Solution Approach 2:
Service ports or access panels act as intermediaries between the under-axle battery packs and maintenance personnel. These access points allow technicians to reach and service the batteries from above or from accessible side locations without needing to access the area directly under the axles.
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
The integration of a structural battery box enhances vehicle functionality, simplifies battery installation and maintenance, optimizes space usage, and improves weight distribution, making it suitable for various applications.
Implementation Method 1
The module includes a battery and a module terminal. The battery box is configured to transfer energy from the module to at least one component of the electrified vehicle
Implementation Method 2
The internal cavity of the battery box comprises a system terminal configured to contact the module terminal of the module to facilitate the transfer of the energy from the module to the component of the electrified vehicle
Data Source
AI summary
An electrified vehicle includes a front subframe, a rear subframe, and a body that connects the front subframe to the rear subframe so that forces acting on the front subframe and the rear subframe are transmitted through the body. The vehicle also includes a housing coupled to an underside of the body between the front subframe and the rear subframe. An energy storage system is enclosed in the housing and includes a battery and a battery interface configured to electrically couple the battery to at least one component of the electrified vehicle.