Heavy-Duty Vehicle Energy Storage Compartment for Transverse Load Absorption
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Solution Overview
Problem
Conventional placement of energy storage systems like batteries or hydrogen fuel tanks in heavy-duty vehicles along longitudinally extending frame rails exposes the frame and connecting brackets to high stress, making them vulnerable to damage and requiring multiple brackets for safe suspension, while also limiting the space for larger energy storage systems.
Innovation Solution
An energy storage compartment is arranged between a pair of longitudinally extending frame rails, comprising longitudinally extending portions forming an encircling load absorbing module that absorbs transverse loads, eliminating the need for transverse stiffeners and allowing larger, uninterrupted energy storage systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If energy storage systems are placed along the longitudinally extending frame rails, then the energy storage system can be positioned in a conventional location, but the frame and connecting brackets are exposed to high stress and require multiple brackets for safe suspension
Solution Approach 1:
The patent introduces a longitudinal beam as an intermediary structural element between the frame rails and the energy storage system. This beam acts as a mediator that distributes and absorbs transverse loads, protecting the frame and connecting brackets from high stress while maintaining the conventional placement location.
Solution Approach 2:
The patent segments the load-bearing function by separating it from the frame structure. The longitudinal beam is introduced as a dedicated load-absorbing component that handles transverse loads independently, allowing the frame to focus on its primary function while the beam manages the additional stress from the energy storage system.
2Reliability
If multiple brackets are used to suspend the energy storage system, then the system can be safely supported, but the structural complexity and number of components increase
Solution Approach 1:
The longitudinal beam serves as an intermediary that reduces the burden on connecting brackets. By absorbing and distributing transverse loads along its length, the beam allows for reduced bracket usage while maintaining suspension safety, thus lowering structural complexity.
Solution Approach 2:
The longitudinal beam provides self-service by inherently absorbing transverse loads through its structural design. This self-load-absorbing capability reduces the dependency on multiple brackets for stress management, simplifying the overall suspension system while maintaining reliability.
3Area of stationary object
If the energy storage system is positioned transverse to the frame rails, then the space utilization is improved, but the energy storage volume is reduced
Solution Approach 1:
The patent resolves this spatial contradiction by transitioning to a longitudinal arrangement of the energy storage system along the frame rails, utilizing the longitudinal dimension of the vehicle. The longitudinal beam enables this orientation by absorbing transverse loads, thereby maximizing energy storage volume while maintaining effective space utilization through optimized longitudinal positioning.
4Device complexity
If conventional frame structure is used without additional load absorbing modules, then the structural design is simplified, but the energy storage system is vulnerable to damage during vehicle operation
Solution Approach 1:
The longitudinal beam acts as a protective intermediary between external transverse loads and the energy storage system. This beam absorbs and distributes impact forces and transverse loads, shielding the energy storage system from damage during vehicle operation while adding minimal complexity to the overall structural design.
Solution Approach 2:
The longitudinal beam provides beforehand cushioning by being pre-positioned and structurally designed to absorb transverse loads before they can reach the energy storage system. This proactive load absorption protects the energy storage system from potential damage during vehicle operation.
Data Source
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AI summary
The present disclosure relates to an energy storage compartment (100) connectable between a pair of longitudinally extending frame rails (200) of a heavy-duty vehicle, the energy storage compartment being arranged to house an energy storage system (300) configured to supply energy to a prime mover of the vehicle for propulsion of the prime mover, wherein the energy storage compartment (100) comprises longitudinally extending portions (400) forming an encircling load absorbing module, the longitudinally extending portions (400) comprising a pair of longitudinally extending side wall portions (402, 404) connectable to the pair of longitudinally extending frame rails (200), a longitudinally extending floor portion (406) and a longitudinally extending roof portion (408), wherein the longitudinally extending portions of the encircling load absorbing module are arranged and configured to, when being subject to a load from the longitudinally extending frame rails, absorb the transversal component of the load.