Patent Publication Number: US-2023158880-A1

Title: Mounting system for accessory units on a vehicle

Description:
TECHNICAL FIELD 
     The invention relates to a mounting device for accessory units on a vehicle and in particular, a flexible and scalable step-less interface. 
     The invention can be applied in heavy-duty vehicles, such as trucks, buses and construction equipment. Although the invention will be described with respect to a goods lorry, the invention is not restricted to this particular vehicle, but may also be used in other vehicles such as heavy duty construction equipment. 
     BACKGROUND 
     Recent development in the automotive area has been focusing on electrical drive solutions; this is true also for heavy-duty vehicles such as trucks, buses and construction equipment. This drives the need for new solutions around driveline, energy storage, construction and assembly of these types of vehicles. Generally, heavy-duty vehicles are often specially designed on a case-by-case basis or have a number of different accessory units installed on the vehicles depending on functionality and type of vehicle. For instance, energy storage systems, like for instance batteries, are generally heavy and take up large volumes in automotive applications. This is especially true for heavy-duty vehicles operating for long hours each day and with heavy loads. Furthermore, these types of vehicles, since they concern smaller manufacturing series, often specially designed solutions and heavy installations, need to be easily assembled during manufacturing but also easily serviced and repaired. 
     Another aspect of mounting of energy storage systems, such as batteries, or other accessories are safety concerns. There is a concern that different parts mounted in or on the vehicle are securely mounted and behave in a predictable manner if the vehicle is subjected to an accident. Thus, there is a need for secure handling of energy storage systems and the like. 
     Thus, there is a need for effective and reliable solutions for mounting of different parts of the vehicle during manufacturing and for servicing the vehicle. The mounting solutions often used today provide cumbersome processes and are quite complex in mounting procedures and mounting arrangements. 
     In DE10217009176, a coupling device for securing a vehicle component to a frame side member of a vehicle frame is discussed; however, in this solution complex alignment of the coupling device is needed. 
     SUMMARY 
     It is an object of the present invention to obviate at least some of the above disadvantages and provide improved system for mounting of energy storage systems or other accessory units to a vehicle frame. Thus, an object of the invention is to provide a system and a method for mounting an energy storage system or accessory unit to a frame of a heavy-duty vehicle. According to a first aspect of the present invention, this object is achieved by a system according to claim  1 , in which a mounting system for mounting at least one accessory unit, such as an energy storage system, ESS, to a vehicle frame is provided. The mounting system comprise at least one side channel attached to the accessory unit, at least one screw-strip comprising a plate with a plurality of screws fitted at pre-defined locations or intervals defined by matching mounting positions of at least one frame-mounted bushing. The screw-strip is displaceable fitted in the side channel. The system further comprises at least one mounting bracket arranged to receive the screws fitted on the screw-strip and to receive a nut for each screw arranged to fixate the mounting system by pressing the screws towards a locking arrangement in the side channel and wherein the bracket is arranged to receive the frame-mounted bushing mounted to a side rail of the vehicle frame. The screw-strip provides a low cost solution for adjusting the position of the accessory unit in relation to the frame and the frame-mounted brackets. 
     The screw strip may provide a frictional breaking function of the mounting system if the vehicle is subjected to a rapid retardation. The frictional breaking function may be determined by the number of screws attached to the screw strip or by a mounting force asserted on each nut/screw joint of the screws mounted to the at least one frame mounted bracket. The braking function provide a more secure and pre-controlled behaviour of the accessory unit in case of a rapid retardation of the vehicle, e.g. in case of an accident. 
     The mounting system may further comprise at least two side channels and at least two screw-strips. The use of two or more channels on each side provide a better alignment, more secure mechanical suspension of the accessory unit, and more controlled behaviour of the accessory unit in case of a rapid retardation. Having two or more side channels provide a mechanically robust solution for mounting large and heavy accessory units to the vehicle. 
     The side channel may comprise a plurality of separate sections attached longitudinally to each other and together forming a continuous length along the at least one accessory unit. The side channel may be provided as an integral part of the accessory unit or attached to a side of the accessory unit. With the system according the present invention, several sections may be attached and easily handled. The different sections may also be different accessory types and still be mounted as a single unit. This is advantageous since it provides a highly flexible mounting solution where different types of accessory units may be mounted to a vehicle using the same mounting system. 
     Each channel may comprise a generally U shaped profile with inwardly protruding flanges acting as locking members for the screw-strip. The at least one side channel may be formed in an extruded metal profile, for example an extruded aluminium profile. This provides the advantage of a low cost means for providing a locking function. 
     In one example, the accessory unit may be an energy storage system, ESS. The mounting system for an ESS has the advantage of easy mounting during initial installation but also reduces the complexity of dismounting and remounting in case quickly changing energy storage system or for service of the ESS and/or the vehicle. 
     The mounting system may further comprise a frame-mounted bushing arranged to be mounted on a side rail of the vehicle and where the bushing comprise a protruding element arranged to receive the mounting bracket. This has the benefit of easily attaching the mounting bracket to the vehicle. 
     In another aspect of the present invention, a vehicle comprising a mounting system according to the present invention is provided. 
     Yet another aspect of the present invention is provided, a method for mounting an accessory unit to a vehicle, comprising the steps of pre-mounting at least one mounting bracket on at least one screw-strip comprising a plurality of screws fitted at pre-defined intervals defined by matching mounting positions of at least one frame-mounted bushing fixed on a side rail mounted to a frame of the vehicle, sliding each at least one screw-strip into a corresponding side channels attached to the accessory unit, securing the screw-strip to the at least one side channel fixating the movement of the screw-strip relative the side channel, and lifting the accessory unit into a position where the mounting-bracket (30) rests on the at least one frame-mounted bushing. This has the advantage of providing a quick and flexible mounting solution for accessory units on to vehicles. 
     Further advantages and advantageous features of the invention are disclosed in the following description and in the dependent claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       With reference to the appended drawings, below follows a more detailed description of embodiments of the invention cited as examples. 
       In the drawings: 
         FIG.  1    is a schematic illustration of a vehicle with a mounting system; 
         FIG.  2    is a detailed schematic of a vehicle frame with the mounting system; 
         FIG.  3    is a schematic 3D view of the mounting system in detail; 
         FIG.  4    is a schematic 3D view of a screw-strip; 
         FIG.  5    is a schematic cross-sectional side view of the mounting system; 
         FIG.  6    is a schematic mounting procedure of the mounting system; and 
         FIG.  7    is a schematic block diagram illustrating a method of mounting an accessory unit to a vehicle. 
     
    
    
     DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS OF THE INVENTION 
     In  FIG.  1   , reference numeral  10  generally shows a heavy-duty vehicle. The exemplified vehicle is shown as a truck arranged for receiving a trailer but other types of trucks, buses, working machines, and construction equipment may be applicable for the present solution. The vehicle in this case is equipped with an accessory unit  20  attached to a frame  11  of the vehicle. The accessory unit is located between the front wheels  12  and rear wheels  13  of the vehicle and mounted to the frame  11  with a mounting system  15 . It should be noted that the accessory unit may be located at other locations on the vehicle different from between the front and rear wheels. The accessory unit  20  may for instance be an energy storage system (ESS) such as a battery pack but other types of accessory types may be of interest for mounting to the vehicle using the present solution. 
       FIG.  2    shows a more detailed view of the accessory unit, such as an energy storage system, mounted to the frame  11  via two side rails  12  using the mounting system  15 . The side rails  12  provide a base structure for mounting equipment and accessories to be used on or with the vehicle. The accessory unit  20 , e.g. the ESS, may comprise one single module or a plurality of modules  21  attached adjacent each other and together forming a continuous unit in the longitudinal direction of the vehicle. 
     In  FIG.  3   , a more detailed view of the mounting system  15  is shown. The mounting system  15  comprise at least one mounting bracket  30  arranged to receive a frame-mounted bushing  50  attached to the frame  11  via a side rail  12  of the frame. The side rail may comprise a plurality of openings (not shown) for receiving fastening elements, such as screws and nuts or similar, for fastening different types of equipment, for instance the frame-mounted bushing  50 . The mounting bracket  30  of the accessory unit  20  is arranged to receive the bushing in such a way to restrict the movement of the accessory unit in a horizontal direction; for instance, the mounting bracket may comprise a receiving cavity (not shown) that receives a protruding element  53  of the frame-mounted bushing. 
     The mounting system further comprise at least one sliding element for receiving the mounting bracket and fit in the side channels providing a flexible and adjustable location of the mounting brackets relative the frame, i.e. the sliding element may slide in the side channels and be fastened at suitable locations in the side channel by flexible locking elements such as screw/nut, self-locking screws, or other similar elements. Such receiving element may for instance be one or more screw-strips  40 , each screw-strip is attached to a side channel  22  that in turn is an integral part of the accessory unit or arranged in an element  45  attached to the accessory unit, for instance as an extruded metal profile, e.g. in aluminium. The side channel runs along the accessory unit at least part of the length of the accessory unit in order to provide a suitable mechanical support of the accessory unit to the vehicle. The side channel comprise a locking arrangement  23  for securing the screw-strip to the mounting bracket  30  to the accessory unit as will be discussed further below. 
     The accessory unit is mounted onto the frame-mounted bushing by lifting the accessory unit up and then lowering it onto the protruding element of the bushing. The mounting bracket may be arranged with a receiving element (not shown) that receives the protruding element of the frame-mounted bushing thus restricting the movement in a horizontal plane. The movement of the accessory unit may further be restricted in the vertical direction by some locking mechanism (not shown). 
     The screw-strip comprise an elongated plate  41  with a plurality screws  42  attached to the screw-strip and each screw is arranged to receive a nut  43  as can be seen in  FIG.  4   . The screws are located at suitable locations or intervals on the screw-strip as matching positions of the at least one frame-mounted bracket  30  attached to the frame  11  via the side rail  12  part of the frame. The screws on the screw-strip mate with the mounting bracket  30  in openings  31  and the screws are attached to the mounting bracket by nuts  43 . The screws are pressed against the side channel  22  locking arrangement  23  when the nuts are tightened and thus fixating the mounting bracket to the accessory unit via the screw-strip. The locking arrangement may for instance comprise a generally U shaped profile with inwardly protruding flanges with an opening that enable the screw to fit within, and acting as locking members for the screw-strip and the locking arrangement may be an integral part of the accessory unit or the element attached to the accessory unit. It should be noted that other fastening means then screws and nuts might be used for attaching the screw-strip to the mounting bracket. 
       FIG.  5    shows a side cut view of the mounting system with the accessory unit  20 , e.g. an energy storage system (ESS), the mounting bracket  30 , and the frame-mounted bushing  50 . The accessory unit  20  comprise in this case a plurality of side channels  22  located in this example a separate element  45  attached to the accessory unit. The frame-mounted bushing comprise a bracket for attachment to the side rail  12  of the frame  11  and the protruding element  53  onto which the mounting bracket rests on. In  FIG.  5   , the locking arrangement  23  is shown more clearly. The side channels  22  are slightly larger than the screw-strips providing an easier sliding of the screw-strips into the side channels during installation of the mounting system to the accessory unit and easier adjustments of the position of the mounting bracket relative the frame-mounted bushings. 
     The accessory unit, for instance an ESS unit, may comprise several units attached to each other and together forming a continuous unit and the side channels may be provided as several units and attached or integrated in the accessory units such as forming continuous channels along the accessory units for the screw-strip to run along. This is illustrated in  FIG.  6   , wherein several side channels  44  are located in or in a plurality of accessory units  21 . In  FIG.  6 A , it is also shown that the screw-strips with the mounting brackets are made to slide into the side channels into a position for mounting the accessory to the frame ( FIG.  6 B ). Since the screw-strip(s) slides easily along the side channels these can easily be adjusted into correct positions or intervals for mounting of the accessory unit to the vehicle. In the example of  FIG.  6   , the accessory unit is a large and potentially heavy unit, thus two combined screw-strips/mounting brackets packages on each side of the accessory unit are used in order to provide a stable and secure mounting solution. 
     The side channels longitudinal direction may be in the travelling direction of the vehicle and by controlling the locking stiffness of the screw-strip in relation to the accessory unit, a controlled mechanical behaviour of the accessory unit  20  in case of rapid retardation, e.g. in case of an accident, may be provided. This may for instance be provided by controlling the torque applied on the nuts securing the screws, the number of screw/nuts used for attachment to the mounting bracket, or by providing a controlled frictional behaviour between each screw and the locking arrangement  23 . Thus, if the vehicle is subjected to a rapid retardation, the accessory unit may be allowed to move relative the frame in a controlled manner and thus reducing the immediate impact on the overall structure of the vehicle. 
       FIG.  7    shows a method of mounting the accessory unit to the vehicle. The method comprise the steps of: 
       701 . The mounting bracket or brackets are pre-mounted on to the screw-strip(s) at the pre-defined intervals defined by matching mounting positioned of the at least one frame-mounted bushing  50  fixed on the side rail  12  mounted to the frame  11  of the vehicle. For instance, as seen in  FIG.  6   , three screw-strips are used for each side of the accessory unit and a plurality of mounting brackets are attached to the screw-strips. 
       702 . When the mounting brackets are attached to the screw-strips, the combined screw-strip/mounting brackets slides into one or more side channels attached to or integrated into the accessory unit. Again referring to  FIG.  6   , one combined package on each side of the accessory unit slides into corresponding side channels. 
       703 . When the screw-strip(s) is at suitable location in the side channel, the screw-strip is secured to the side channel. For instance, by fastening the nut  43  in turn pressing the screw  42  head towards the locking arrangement  23 . In this way, the movement of the mounting bracket(s) and screw-strip(s) are secured and locked relative the side channels and accessory unit. 
       704 . In a final step, the accessory unit  20  together with the mounting system is lifted so as the protruding element  53  of the mounting bracket is lifted onto the frame-mounted bushing of the vehicle and thus the mounting bracket rests on the frame-mounted bushing. 
     It is to be understood that the present invention is not limited to the embodiments described above and illustrated in the drawings; rather, the skilled person will recognize that many changes and modifications may be made within the scope of the appended claims.