Vehicle Energy Module Support Structure for Mixed BEV and FCEV Assembly
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Solution Overview
Problem
The vehicle industry faces challenges in reducing CO2 emissions and managing diverse installation components, tools, and processes for mixed model assemblies of battery electric vehicles and hydrogen fuel-cell electric vehicles, which increases investment costs and complicates production.
Innovation Solution
A modular system with energy source modules having a rectangular cross-section, allowing for scalable installation and shared equipment and tools, where gas tanks and battery packs can be installed using the same support structure and tools, enabling flexible combinations based on vehicle needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If cylindrical hydrogen gas tanks are mounted at a designated holding structure laterally of the frame rails, then the hydrogen storage function is achieved, but the installation process becomes complex and requires diverse installation components and tools
Solution Approach 1:
The support structure is designed with universal mounting brackets that can accommodate both cylindrical hydrogen tanks and rectangular battery packs using the same installation components and tools. The brackets are configured to interface with both tank types through standardized mounting points, eliminating the need for separate installation systems for different energy source modules.
Solution Approach 2:
The support structure is divided into modular components including adjustable brackets and standardized mounting interfaces. This segmentation allows the same basic structure to be configured for different energy source types without requiring complete redesign or diverse tool sets for installation.
2Adaptability or versatility
If mixed model assembly of battery electric vehicles and hydrogen fuel-cell electric vehicles is performed, then vehicle variety is achieved, but investment costs increase due to diverse installation components and tools
Solution Approach 1:
The support structure and installation system are designed as universal platforms that can handle both battery packs and hydrogen tanks. This multi-functionality allows a single production line to manufacture both BEV and FCEV models without requiring separate tool sets or installation components, thereby reducing investment costs while maintaining vehicle variety.
Solution Approach 2:
The support structure incorporates adjustable and reconfigurable elements that can be dynamically adapted during the assembly process to accommodate different energy source modules. This dynamic capability enables the same production line to switch between different vehicle models without requiring complete tool changes.
3Quantity of substance
If traditional cylindrical hydrogen tanks are used, then hydrogen storage capacity is achieved, but the same support structure and tools cannot be used for battery packs and gas tanks
Solution Approach 1:
The mounting brackets are designed with universal interfaces that can securely hold both cylindrical hydrogen tanks and rectangular battery packs. The same brackets and fastening mechanisms work for both energy source types, achieving installation process unity while maintaining the hydrogen storage capacity of cylindrical tanks.
Data Source
AI summary
A modular system for a vehicle. The modular system includes a plurality of energy source modules configured to be connected to or included in a propulsion system of a vehicle, each one of the energy source modules having a rectangular cross-section. The modular system also includes a support structure operatively connectable to a chassis of the vehicle, the support structure defining a space for receiving said energy source modules. At least one of the energy source modules is a pressurized vessel containing a gas. The invention also relates to a vehicle and to an installation method.