Fold-Out Vehicle Step Layout for Battery Space and Crash Protection
Solution Overview
Problem
Existing step arrangements in BEV trucks compromise battery space, crash protection, and ergonomics, particularly for short drivers accessing the rear deck.
Innovation Solution
A step arrangement with a frame, an upper step, and a lower step connected by linking elements, allowing pivotable movement around different geometrical axes, providing ergonomic accessibility while maintaining crash protection and compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If cut-outs are provided in battery packs to form steps, then step functionality is achieved, but battery volume and driving range are reduced
Solution Approach 1:
The step arrangement is divided into separate components (frame, upper step, lower step, linking elements) that aremovably connected rather than being integrated into the battery pack structure. This allows the steps to function independently without compromising battery volume or requiring cuts in battery packs.
Solution Approach 2:
The step arrangement uses vertical stacking with the upper step positioned above the lower step, utilizing the vertical dimension to provide two stepping surfaces without occupying additional horizontal space that would reduce battery volume.
2Ease of operation
If foldable steps are provided with two steps one above the other, then ergonomic accessibility is improved, but crash protection structure ability is reduced
Solution Approach 1:
The step arrangement transitions from a static structure to a dynamic one where the upper step can pivot between a folded position (storing against the frame) and an unfolded position (providing two steps). This dynamic configuration allows the structure to provide ergonomic benefits when needed while minimizing interference with crash protection when folded.
Solution Approach 2:
The upper step nests against the frame in the folded position, with the lower step following the movement to maintain compact configuration. This nesting arrangement minimizes the space occupied by the step arrangement when not in use, preserving crash protection structure integrity.
3Strength
If only one step is provided, then crash protection structure ability is improved, but ergonomic accessibility is reduced
Solution Approach 1:
The movable connection between the upper step and frame allows the step arrangement to dynamically adjust between providing one step (when folded) or two steps (when unfolded), enabling the structure to adapt to different operational requirements without compromising crash protection when folded.
4Volume of moving object
If the upper step is pivotable around a first geometrical axis and the lower step around a second geometrical axis perpendicular to the first, then compact space utilization is achieved, but device complexity increases
Solution Approach 1:
The linking element combines the functions of connecting the lower step to the upper step and enabling the lower step to pivot independently around a second geometrical axis. This merging of functions achieves compact space utilization without proportionally increasing overall device complexity.
Data Source
AI summary
A step arrangement comprises a frame, an upper step, a lower step, and a linking element. The upper step is, relative to the connected frame, pivotable around a first geometrical axis to allow the upper step to be moved from a folded position in a storage state of the step arrangement to an unfolded position, the lower step following the movement of the upper step. The linking element, interconnecting the upper and lower steps, is, relative to the upper step, pivotable around a second geometrical axis which extends in a direction which is substantially perpendicular to the direction of extension of the first geometrical axis, in order to allow the lower step to be moved along an arc of a geometrical circle so that the lower step becomes spaced apart from the upper step in a completely unfolded position of the lower step in in-use state of the step arrangement.