Underslung Battery Pack Mounting With Isolators and Access Steps
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Solution Overview
Problem
Existing battery pack mounting systems for vehicles, particularly refuse vehicles, lack efficient and stable configurations that accommodate multiple batteries and provide easy access for maintenance, while withstanding impact forces.
Innovation Solution
A chassis design with spaced rails and a battery assembly that includes a housing with medial and lateral portions, supported by a mounting assembly with isolators to absorb forces, allowing multiple batteries to be positioned and secured laterally, with access steps for technicians.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a battery assembly is mounted on the chassis of a refuse vehicle, then the vehicle gains electrical energy storage capability, but the mounting system must withstand impact forces and provide stable support
Solution Approach 1:
The patent applies beforehand cushioning by incorporating energy absorption elements (such as rubber isolators or spring dampers) between the battery assembly and chassis before impact occurs. These elements are pre-installed in the mounting system to cushion and dissipate impact forces when the vehicle operates on uneven terrain or experiences sudden stops, protecting the battery assembly from damage while maintaining reliable mounting stability
Solution Approach 2:
The patent uses an intermediary mounting system that includes isolation elements positioned between the battery assembly and the chassis. These intermediary components (such as rubber blocks, spring dampers, or elastomeric isolators) act as mediators that decouple the rigid connection, allowing the battery assembly to be securely mounted while absorbing vibrations and impact forces from the rough operating environment of refuse vehicles
2Quantity of substance
If multiple batteries are positioned within the battery assembly housing, then energy storage capacity increases, but access for maintenance becomes more difficult
Solution Approach 1:
The patent applies segmentation by dividing the battery assembly into modular sections or compartments, each containing one or more batteries. This modular segmentation allows maintenance personnel to access and service individual battery modules independently without needing to disassemble the entire assembly, making it easier to maintain multiple batteries while preserving energy storage capacity
Solution Approach 2:
The patent utilizes another dimension by arranging batteries in a three-dimensional configuration within the housing, with some batteries positioned at different vertical levels or depths. This spatial arrangement, combined with accessible openings or removable panels in the housing, allows maintenance access from multiple directions, facilitating easier servicing of multiple batteries packed within the assembly
3Reliability
If the battery assembly housing includes lateral portions extending beyond the rails, then mounting stability improves, but the overall vehicle width increases
Solution Approach 1:
The patent applies local quality by providing lateral portions or extensions of the battery assembly housing only at specific locations where mounting stability is needed, rather than uniformly increasing the width of the entire assembly. These localized lateral extensions are positioned to engage with the chassis rails or mounting structures, providing stable support while minimizing the overall width increase of the vehicle
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 solution provides a stable and accessible battery mounting system that withstands impact forces and facilitates easy maintenance, enhancing the operational reliability and usability of refuse vehicles.
Implementation Method 1
the isolator is configured to absorb forces or impacts being transferred between the medial portion, the first lateral portion, the second lateral portion and the chassis
Data Source
AI summary
A refuse vehicle includes a chassis including a plurality of rails, a front and rear tractive assemblies coupled to the chassis, and a battery assembly. The battery assembly is coupled to the chassis between the front and rear tractive assemblies. The battery assembly includes a battery housing, a mounting assembly, and a support. The mounting assembly is coupled to the battery housing and the plurality of rails. The mounting assembly includes a isolator configured to stabilize the battery assembly. The support is positioned within the battery housing and extends along a midpoint of the battery housing. The isolator absorbs horizontal and vertical impact forces introduced to the battery assembly.