EP4232306A1

EP4232306A1 - Improved front hanger for a heavy vehicle suspension system

Info

Publication number: EP4232306A1
Application number: EP21794648.2A
Authority: EP
Inventors: Christian Konrad; Florian Koeberle; Michael GUNGL; Fabian Schmidt
Original assignee: Iveco Magirus AG
Current assignee: Iveco Magirus AG
Priority date: 2020-10-22
Filing date: 2021-10-22
Publication date: 2023-08-30
Also published as: IT202000025009A1; WO2022084936A1

Abstract

Suspension system for a heavy vehicle comprising a front hanger (10) for a heavy vehicle, such front hanger (10) comprising an upper portion (11'), a lower portion (11'') and an intermediate portion (11''') connecting together the upper and lower portions (11', 11''). The upper portion (11') being configured to be fix the front hanger (10) to a chassis of said vehicle, at least one between the upper portion (11'), the lower portion (11'') and the intermediate portion (11''') being configured to allow the connection of an element (7', 7'') of a suspension system (5) of vehicle, the upper portion (11') and the lower portion (11'') comprising at least a fixation point (16, 17, 23) configured to allow the fixation of a battery module (6) of the vehicle.

Description

“IMPROVED FRONT HANGER FOR A HEAVY VEHICLE SUSPENSION SYSTEM” CROSS-REFERENCE TO RELATED APPLICATIONS This patent application claims priority from Italian patent application no. 102020000025009 filed on 22/10/2020, the entire disclosure of which is incorporated herein by reference. TECHNICAL FIELD The present invention concerns a front hanger for a suspension system, in particular a front hanger for a heavy vehicle suspension system provided with an electronic traction. BACKGROUND OF THE INVENTION Heavy vehicles such road transport vehicles, e.g. trucks, are more and more electrified for reducing their polluting emissions. In particular, such vehicles may be hybrid vehicles or purely electric vehicles. In particular, the electrified vehicles comprises at least an electric axle, i.e. an axle provided with electric machines such as motors/generators configured to impart a torque on the axle to allow its motion or to recharge battery modules of the vehicle when this latter is braking. Such battery modules are usually placed in the proximity of the electric machines of the electric axle in order to provide energy exchange with electric machines in an efficient way. However, as known, an axle of a vehicle is connected to the chassis of this latter via a suspension system configured to dampen the forces acting between the road and the chassis. If a vehicle is provided with an electric axle as described above, the presence of the electric batteries does not allow the use of standard front hangers that are used to give support to different elements of the suspension. Moreover, the presence of peculiar fixing means for stably connecting the electric batteries to the chassis reduces the useful space on the vehicle for the elements of the suspension. Therefore, the need is felt to provide a compact and economic way to allow the fixation of the suspension elements of a heavy vehicle and the electronic batteries in the proximity of an electric axle of the such heavy vehicle. An aim of the present invention is to satisfy the above mentioned needs in a compact, optimized and cost effective way. SUMMARY OF THE INVENTION The aforementioned aim is reached by a front hanger, a suspension system and a vehicle as claimed in the appended independent claims. Preferred embodiments of the invention are realized according to the claims dependent on or related to the above independent claim. BRIEF DESCRIPTION OF DRAWINGS For a better understanding of the present invention, a preferred embodiment is described in the following, by way of a non-limiting example, with reference to the attached drawings wherein: ● Figure 1 is a perspective view showing a front hanger according to the present invention; ● Figure 2 is a perspective view showing a portion of a vehicle provided with electric battery modules and a front hanger according to the present invention; ● Figure 3 is a top view showing the portion of vehicle of figure 2, with parts removed for sake of clarity; ● Figure 4 is a lateral view showing the portion of vehicle of figure 2, with parts removed for sake of clarity; ● Figures 5 and 6 are enlarged perspective views showing details of connection of electric battery modules of a vehicle with the front hanger according to the present invention. DETAILED DESCRIPTION OF THE INVENTION Figure 2 shows a portion of a chassis 1 of a heavy vehicle such as truck, comprising as known a pair of side members 2 extending longitudinal along a longitudinal axis A of the vehicle. The chassis 1 is connected via a suspension system 5, partially shown, to an electric axle 4, shown only schematically. As per se known, the suspension system 5 dampens the relative movements between the chassis 1 and the electric axle 4 that is configured to provide torque to wheels, not shown, carried by the electric axle 5 itself. The chassis 1 is furthermore configured to carry at least one battery module 6 configured to be electrically connected to the electric axle 4 to exchange electric energy. In particular, as known, the electric axle 4 is provided with electric machines that are fed by the at least one battery module 6 to provide torque to the wheels carried by the axle 4 or to receive electric energy generated by the electric machines when the vehicle is braking. In the exemplarily shown embodiment, the chassis 1 carries two battery modules 6 in particular a battery module 6 for each side member 2. More preferably, each battery module 6 is carried externally with respect to each side member 2. The suspension system 5 comprises, as known, a plurality of elements 7', 7'', 8 configured to connect the electric axle 4 to respective side members 2, 3 in order to dampen/limit a relative movement along a direction along axis A or a different axis. In particular, the proposed suspension system 5 comprises longitudinal right and left rods 7', 7'' configured to longitudinally limit, i.e. along axis A, a movement of electric axle 4 and a V-rod 8 provided with two inclined arms with respect to axis A and configured to limit a movement on a transversal axis perpendicular to axis A. More in detail, the V-rod 8 comprises a right arm 8' and a left arm 8''. Clearly, the suspension system comprises other elements such as air bellow or dampers (not shown) to limit a vertical motion of the electric axle 4 and here not shown and described for simplicity. The V-rod 8 is connected to side members via a cross member 9 as shown in figure 3. Such connection will not further be described in further detail for sake of brevity. Instead, longitudinal right and left rods 7', 7'' are connected to the respective side member 2, 3 via a respective front hanger 10. According to the invention, each front hanger 10 is configured to allow the connection of at least one element of the suspension system 5, i.e. in the described embodiment the longitudinal right and left rods 7', 7'', to the respective side member 2, 3 of chassis 1 and to allow the fixation of a battery module to the respective side member 2, 3 of chassis 1. In particular, such suspension elements and the battery module can be fixed at least in between the upper portion, the lower portion and the intermediate portion. In greater detail, as shown in figure 1, the front hanger 10 comprises a substantially flat element 11 provided with an upper portion 11' and a lower portion 11''. The upper portion 11' and the lower portion 11'' are connected by an intermediate portion 11''' and, preferably, they are all realized as one piece. More preferably, the flat element 11 defining the front hanger 10 is a monolithic element realized in metallic material by casting. The lower portion 11'' extends long a vertical axis perpendicular to axis A starting to upper portion 11' and has a transversal cross section that is transversally bigger but longitudinally smaller with respect to upper portion 11'. The intermediate portion 11''' has cross-section having a tapered profile to join the upper portion 11' and the lower portion 11''. The upper portion 11' is configured to be securely fixed to the respective side member 2, 3. In particular, the upper portion 11' defines a plurality of holes 12 configured to allow the passage of a fixation element such as a threaded element, a dowel or the like. In particular, the upper portions defines a first plurality of holes 12 and a second plurality of holes 12, i.e. two separate group of holes, that are realized on opposite longitudinal portions of the upper portion 11 with respect to a transversal plane α. Accordingly, it is defined a rear plurality of holes 12 and a front plurality of holes 12. The lower portion 11'' is configured to allow the connection of an extremity portion of a respective longitudinal rod 7', 7'', in particular through a movable connection. In greater detail, the movable connection is a hinge connection 13 configured to allow the movement of the extremity portion of the longitudinal rod 7', 7'' about a transversal axis B. In particular, the lower portion 11'' bifurcates thereby defining an outer leg 14' and an inner leg 14'' respectively positioned outer and closer with respect to a longitudinal plane β. Each leg 14', 14'' defines on a terminal portion thereof a through hole 15 configured to allow the fixation of the hinge connection 13, as shown in greater detail in figures 4 and 6 and not further described for sake of brevity. Each front hanger 10 further defines both in the upper portion 11' and in the lower portion 11'' at least a fixation point for a battery module 6 of the vehicle. In particular, according to the disclosed embodiment, the upper portion 11' defines a pair of fixation points for the battery module 6 and the lower portion defines a single fixation point for such battery module 6. In greater detail, the upper portion 11' defines a first and second fixation points 16, 17 configured respectively to secure the battery module 6 to the front hanger 10 thereby supporting a longitudinal and a vertical possible movement of this latter. According to the described embodiment, the first fixation point 16 comprises a cantilevered portion 18 that is preferably substantially flat and extending horizontally, i.e. in a plane perpendicular to planes α and β getting far from upper portion 11'. In particular, such cantilevered portion 18 extends from an upper edge of front hanger 10. Such cantilevered portion 18 defines a hole 19 configured to allow the fixation of the battery module, via a fixation element such as a threaded element, a dowel or the like. According to the described embodiment, the second fixation point 17 comprises a flanged portion 21 that is preferably substantially flat and extending transversally, i.e. along plane α/axis B direction and getting far from upper portion 11'. Such flanged portion 21 defines a plurality of holes 22 configured to allow the fixation of the battery module, via a fixation element such as a threaded element, a dowel or the like. Referring to lower portion 11'', it defines a single fixation point 23 configured to secure the battery module 6 to the front hanger 10 thereby supporting a longitudinal and a vertical possible movement of this latter. According to the described embodiment, the single fixation point 23 comprises a protrusion 24 that is configured to define a hole 25 configured to allow the fixation of the battery module, via a fixation element such as a threaded element, a dowel or the like. In particular, hole 25 is parallel to transversal axis B and, preferably, the protrusion 24 is realized in the outer leg 14' of the lower portion 11''. It is furthermore noticed that the fixation points 16, 17 and 23 and the holes 12 are all faced towards the environment, i.e. they are realized on a side of the front hanger 10 that is opposed to the side in contact with the side member 2, 3. According to the above described, both the front hanger 10, the longitudinal rods 7', 7'' and the battery modules 6 are placed opposite with respect to the space comprised by the side members 2, 3. The operation of the above described front hanger 10 is the following. When fixed via holes 12 to the respective side member 2, 3, the front hanger 10 can be used to securely fix the respective battery module 6 to the chassis 1 in a simple and quick way. In view of the foregoing, the advantages of a front hanger, a suspension system and a vehicle comprising such front hanger according to the invention are apparent. Thanks to the presence of the fixation points 16, 17 and 23 the front hanger 10 allow the support of the vertical, horizontal and rotation possible movements of the battery modules in a sturdy and stable way. Moreover, since further brackets or hangers are provided to secure the battery modules to the chassis 1, the space around this latter is not wasted since the proposed front hanger 10 can be substituted to the already known one, having substantially the same overall dimensions. If the battery modules are not present on the vehicle or only a single battery module is present, the provided fixation points 16, 17 and 23 may be used for securing other elements of the heavy vehicle to its chassis 1. It is clear that modifications can be made to the described front hanger, suspension system and vehicle comprising such front hanger, which do not extend beyond the scope of protection defined by the claims. For example, the fixation points 16, 17 and 23 may comprise plates/walls/protrusions having different shapes, allowing a plurality of fixation holes according to the specific fixation way of the battery module. Moreover, the overall described portions of the front hanger 10 may be varied according to the typology of suspension system.

Claims

CLAIMS 1.- Suspension system (5) configured to operatively connect an electric axle (4) of a heavy vehicle to a chassis (1) thereof, said suspension system (5) comprising a front hanger (10), said front hanger (10) comprising an upper portion (11'), a lower portion (11'') and an intermediate portion (11''') connecting together the upper and lower portions (11', 11''), said upper portion (11') being configured to fix said front hanger (10) to said chassis (1) at least one between the upper portion (11'), the lower portion (11'') and the intermediate portion (11''') being configured to allow the connection of an element (7', 7'') of said suspension system (5) said upper portion (11') and said lower portion (11'') comprising at least a fixation point (16, 17, 23) configured to allow the fixation of a battery module (6) of said heavy vehicle.

2.- Front hanger according to claim 1, wherein said fixation point (16, 17, 23) define at least a hole (19, 22, 25) configured to allow the insertion of a fixation element for fixing said battery module (6).

3.- Front hanger according to claim 1 or 2, wherein said fixation point is realized as a plate (16, 17) extending from said upper or lower portions (11', 11'').

4.- Front hanger according to claim 1 or 2, wherein said fixation point is realized as a protrusion (23) extending from said upper or lower portions (11', 11'').

5.- Front hanger according to any of the preceding claims, wherein said upper portion (11') defines a plurality of holes (12) for fixing said front hanger (10) to said chassis (1).

6.- Front hanger according to claim 5, wherein holes (12) are grouped in a first and a second plurality of holes (12), said first and second plurality being realized in opposite rear and front portions of said upper portion (11') with respect to a transversal plane (α) of said front hanger (10).

7.- Front hanger according to claim 4, wherein said plate (16) is a horizontal plate (18) extending horizontally from an upper edge of said upper portion (11').

8.- Front hanger according to claim 4 or 7, wherein said plate (17) is a transversal plate (21) extending parallel to a transversal plane (α) of said front hanger (10).

9.- Front hanger according to any of the preceding claims, wherein said lower portion (11'') bifurcates into a first and a second leg (14', 14'') configured to house a hinge connection (13) to connect said suspension element (7', 7'').

10.- Front hanger according to claim 8, when depending on claims 3, 6 or 7, wherein said protrusion (23) is realized in one of said first and a second leg (14', 14'').

11.- Front hanger according to claim 9, wherein said protrusion (23) is provided with a hole (25) having an axis parallel to the axis of said hinge connection (13).

12.- Heavy vehicle comprising a chassis (1) and an electric axle (4) operatively carried by a suspension system (5) to said chassis (1), said heavy vehicle comprising at least a battery module (6) configured to be electrically connected to said electric axle (4), said heavy vehicle comprising suspension system according to any of the preceding claims.