Attach the accumulator container to the frame and carry every load the accumulator can put into it.
Ten load-based mounts, welded to the accumulator side walls rather than bolted, positioned for serviceability.
Welded over bolted because welding keeps the container serviceable and increases tear-out area. Single bolt over two bolt because a single bolt is more serviceable. Aluminium over steel because aluminium welds to aluminium far more easily, at a cost of about 1.4 lb across all ten mounts and roughly half the strength; the material moved from steel to 7075 aluminium to 6061 once welding was settled. Larger corner fillets and thicker flanges lowered peak stress across iterations.
Each attachment point including any brackets, backing plates and inserts must withstand 15 kN minimum in any direction. Mount distance from the internal corners of the battery section affects how the mounts react to stresses generated by the battery.
Each mount validated independently in three modes, fixed at a 0.25 in weld perimeter: static shear with force distributed over the washer area, pull-out with force distributed as tear-out on the bolt hole, and bending with force distributed in bending on the bolt hole. The weakest mount position and geometry were identified and analysed specifically.
Milled on the CNC, then welded to the accumulator side walls.
6061-T6 aluminium.
None recorded. This part has no entry in Knowledge_Transfer/Issue Logging/Fault Vault.xlsx, in either Issue Log.xlsx, in CR22/Issue Tracking/Shakedown 7-15-23.xlsx, or in any design review issue list found in CrimsonStorage or Box.
0.18 lb each, 1.8 lb for all ten. Quantity per car, as costed: 8
Nothing in CrimsonStorage covers these yet.