WO2022269458A1

WO2022269458A1 - Improved suspended support structure for a heavy vehicle

Info

Publication number: WO2022269458A1
Application number: PCT/IB2022/055705
Authority: WO
Inventors: Philipp-Johannes KONOLD; Matthias MORATH; Cihan DERE; Christian Krug
Original assignee: Iveco Magirus Ag
Priority date: 2021-06-21
Filing date: 2022-06-20
Publication date: 2022-12-29
Also published as: IT202100016172A1

Abstract

Vehicle having at least a partial electric traction, said vehicle comprising a chassis (1) provided with a pair of side members (3, 4) extending along a longitudinal axis (A) of the vehicle and a plurality of heavy modules (2), the vehicle comprising a suspended support structure (5) for supporting the heavy modules (2), that is fixedly carried by the side members (3, 4) and comprises a plurality of transversal walls (7a, 7b) extending transversally with respect to the side members (3, 4) and fixedly carried by this latter the suspended support structure (5) supporting forces and loads acting between heavy modules (2) and said side members (3, 4).

Description

"IMPROVED SUSPENDED SUPPORT STRUCTURE FOR A HEAVY VEHICLE"

Cross-Reference to Related Applications

This patent application claims priority of Italian Patent Application No. 102021000016172 filed on June 21, 2021, the entire disclosure of which is incorporated herein by reference.

Technical Field of the Invention

The present invention concerns a suspended support structure for a vehicle, in particular for a heavy vehicle.

The present invention finds its preferred, although not exclusive, application in supporting batteries of a heavy vehicle having at least a partial electric traction.

State of the Art Heavy vehicles such as trucks are more and more electrified in order to reduce the use of internal combustion engine in view of their polluting emissions.

The electrification foresees the presence of electrical machines configured to provide torque to the wheels of the vehicle and related batteries configured to store electrical energy to be used/provided by the electric machines.

The batteries are usually carried by the chassis of the vehicle and are therefore exposed to the loads acting on this latter.

In particular, the number of batteries for a heavy vehicle is high and they are bulky and heavy, for example 500 kg each and have a dimension of 700 x 850 x 670 mm. Accordingly, it is difficult to support the batteries on standard chassis because their load will overcome the stress resistance of the chassis 1.

Known solutions foresees the presence of reinforcing means that occupies space, increases costs and are not efficient to support batteries. Furthermore, such fixations are not suitable for avoiding the direct transmission of loads from the frame to the batteries.

Therefore, the need is felt to increase the safety of the installation of the batteries on heavy vehicle without increasing manufacturing costs and its weight.

An aim of the present invention is to satisfy the above mentioned needs in a cost effective and optimized way.

Subject and Summary of the Invention

The aforementioned aim is reached by a suspended support structure and a vehicle as claimed in the appended set of claims. Brief Description of the 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 of a suspended support structure of the present invention;

• Figure 2 is a top view of the suspended support structure of figure 1;

• Figure 3 is a rear view of a portion of the suspended support structure of figure 1;

• Figures 4 and 5 are perspective views of a portion of the suspended support structure of figure 1 in an unloaded and a partially loaded condition;

• Figures 6 and 7 are further perspective views of a portion of the suspended support structure of figure

1 in an unloaded and a loaded condition;

• Figure 8 is a perspective enlarged view of an element of the suspended support structure; and

• Figure 9 is a bottom view of a portion of the suspended support structure with focus of the element of figure

8.

Detailed Description of Preferred Embodiments of the Invention

Figure 1 discloses a chassis 1 for a heavy vehicle (not shown) such as a truck. In the following the description will be referred to supporting battery module but it is clear that the system of the invention may be used to support other bulk and heavy modules such as tanks.

The aforementioned heavy vehicle has at last a partial electric traction and therefore comprises a plurality of battery modules 2 carried by chassis 1 in a suspended way. In particular, as per se known, the chassis 1 comprises a pair of side members 3, 4 extending parallel with respect to a longitudinal axis A of the vehicle and preferably symmetrically with respect to this latter. In particular, referring to the provided drawings, it may be defined a right side member 3 and a left side member 4, with reference to axis A.

As per se known, the right and left side members 3, 4 have a C-shaped cross-section, i.e. each comprise a lateral wall 3a, 4a, an upper wall 3b, 4b and a lower wall 3c, 4c.

The vehicle is provided with a suspended support structure 5 that is carried by side members 3, 4 and that defines a plurality of housings 6 (configured to house a heavy module such as the described battery module 2) and disposed longitudinally and transversally adjacent one with respect to the other, i.e. defining at least one row comprising at least two housings 6. In particular, the at least one row comprises at least two housings 6 realized outer with respect to the space comprised by side members 3, 4.

Advantageously, the suspended support structure 5 comprises transversal walls 7 that are fixedly carried by the respective side member 3, 4 and extend transversally with respect to longitudinal axis A.

In detail, the suspended support structure 5 comprises external transversal walls 7a that extends from the respective side member 3, 4 towards environment and internal transversal walls 7b that extends between the side members 3, 4. In particular, the transversal walls 7 and the side members 3, 4 defines the housings 6; accordingly, for each row of housings 6 it is present an inner housing 6 that is transversally delimited by side members 3, 4 and longitudinally delimited by at least one internal transversal wall 7b and a pair of outer housings 6 that are, each, transversally delimited by one of side members 3, 4 by one side and opened on the opposite to the environment and longitudinally delimited by external transversal walls 7a.

According to the disclosed embodiment, the support structure 5 comprises six external transversal walls 7a and a plurality of internal transversal walls 7b disposed in a manner to defined a three rows of three battery modules matrix along longitudinal axis A and the transversal direction to this latter.

In detail, the external transversal walls 7a comprises a front single external transversal wall 7a and a single rear external transversal wall 7a and two pairs of external transversal walls 7a disposed between the front and rear single external transversal walls 7a. Such pairs are equally distanced between them and between the front and single external transversal walls 7a. In particular, each pair comprises two external transversal walls 7a faced in contact one with respect to the other along the longitudinal direction.

Advantageously, each external transversal walls 7a comprises a fixation portion 8, a main plate 9 and a coupling portion 10.

The fixation portion 8 preferably comprises a plate that extends parallel to axis A and that may be fixed to the respective side member 3, 4. In particular such plate defines a plurality of holes to housed threaded means for fixing the latter to the side member 3, 4. The fixation portion 8 has a vertical extension that is substantially the same as the side member 3, 4.

The main plate 9 extends cantilevered with respect to the side member 3, 4, i.e. transversally, from a longitudinal edge of the fixation portion 8 and preferably perpendicular to this latter. The main plate 9 has preferably a quadrangular shape, more preferably squared, and extends vertically below with respect to the side member 3, 4. Such shape is optimized to guarantee sufficient stiffness in case of crash impacts on the chassis 1.

Preferably, the main plate 9 defines at least a hole 9a suitable for reducing the weight of the main plate 9 itself without decreasing its mechanical stiffness.

The coupling portion 10 comprises a wall extending in longitudinal direction from at least part of the perimeter edge of the main plate 9 on the opposite part of the fixation portion 8. In particular, in the disclosed embodiment, the coupling portion 10 comprises a wall extending along longitudinal direction from two of the sides of the main plate 9, along their entire extension and namely the outward and the bottom side and from part of another side, namely the inward side.

According to the above, then the coupling portion 10 comprises a wall that defines a vertical portion 10', a bottom portion 10'' and an inner portion 10'''. In particular, such coupling portion 10 extends towards the opposite external transversal walls 7a into housing 6.

Preferably, the external transversal walls 7a are realized each as one piece and in metallic material.

It is furthermore noticed that on the vertical portion 10' and on the bottom portion 10'' of the coupling portion 10 holes 11 are realized to allow the connection of protection elements for battery modules 2. In particular the vertical portion holes 11 may be configured to allow the connection of a side impact assembly (not shown) while the bottom portion holes 11 may be configured to allow the connection of skid plates for protecting the impact from ground.

The suspended support structure 5 further comprises a stabilizer bar 12 configured to be connected between two external transversal walls 7a passing underneath side members 3, 4 in a manner to not collide with the electric battery module 2 housed in the inner housing 6. In particular, such stabilizer bar 12 is connected via respective movable connections 13 to respective lower sides of the main plate 9 of each external transversal walls 7a.

As best shown in figures 8 and 9, the stabilizer bar 12 comprises a central portion 12a and a pair of extremities portions 12b that defines the respective movable connections 13 with the main plate 9 of the external transversal walls 7a.

Advantageously, the central portion 12a has a substantially "T-shaped" cross section, i.e. comprises a vertical plate 12a' and a horizontal plate 12a'' that extends on a bottom edge of the vertical plate 12a'. The horizontal plates 12a'' may be used for supporting skid plates (not shown) to protect the battery modules from ground impacts.

The extremities portions 12b preferably comprises an eyelet 12b' realized in a terminal portion of the vertical plate 12a' of the central portion 12a. The extremities portions 12b further comprises a pin 15 that is housed within the eyelet 12b' and parallel to its axis, preferably coaxial, and connected to the eyelet 12b' via a rubber bearing 16. Accordingly, the eyelet 12b' is configured to house the rubber bearing 16 that inner houses the pin 15. Therefore, the rubber bearing 16 is an annular rubber bearing 16.

The pin 15 cooperates with cantilevered portions 17 hat are fixedly carried by coupling portion 10, in particular by inner portion 10'''. In detail, as can be appreciated by figure 10, each inner portion 10 carries a cantilevered portion 17, preferably shaped as a pin, on the side opposite to main plate 9.

The pin 15 is arranged to the cantilevered portion 17 so that is may rotate about an axis B that is parallel to axis A. Front and rear external transversal walls 7a that does not foresees the presence of coupling portion 10 of another plate 7 to provide a support for pin 15, may be provided with an auxiliary flange 19 configured to define support for pin 15 on the side opposite to inner portion 10" '.

Coming into details to internal transversal plates 7b, the suspended support structure 5 comprises four internal transversal plates 7b. In particular, the suspended support structure 5 comprises furthermore and a front and a rear cross-members 21, 22, wherein at least one of the front and rear cross-members 21, 22 is preferably placed in linear correspondence to the external transversal walls 7a.

In detail, the suspended support structure 5 a front cross-member 21 and a rear cross-member 22 and two pairs of internal transversal walls 7b disposed between the front and rear cross-members 21, 22 along longitudinal axis A. Such pairs are equally distanced between them and between the front and rear cross-members 21, 22. In particular, each pair comprises two internal transversal walls 7b faced in contact one with respect to the other along the longitudinal direction.

Preferably, each internal transversal walls 7b comprises a pair of fixation portions 23 and an intermediate portion 24.

The fixation portions 23 preferably comprises a plate that extends parallel to axis A and that may be fixed to the respective side member 3, 4. In particular such plate defines a plurality of holes to housed threaded means for fixing the latter to the side member 3, 4. The fixation portion has a vertical extension that is substantially the same as the side member 3, 4.

The intermediate portion 24 extends cantilevered with respect to the side member 3, 4, i.e. transversally, from a longitudinal edge of the fixation portions 23 and preferably perpendicular to these latter. The intermediate portion 24 has a quadrangular shape, preferably rectangular, and extends vertically the same as the side member 3, 4.

Preferably, the intermediate portion 24 defines at least a hole 25 suitable for reducing the weight of the intermediate portion 24 itself without decreasing its mechanical stiffness.

Front and rear cross-members 21, 22 may be realized of any shape provided that they do not protrude within housing 6, i.e. they may interfere with battery modules.Accordingly, they comprise a coupling portions 21a, 22a configured to be fixed to the respective side members 3, 4 and an intermediate portion 21b, 22b configured to be connected to its extremity to the coupling portions 21a, 22a. In particular, the intermediate portions 21b, 22b have each a C-shaped cross section with the opened portion faced to the opposite with respect to the housing 6, i.e. the vertical wall of the C-shaped cross-section is faced to the housing 6. The suspended support structure 5 further comprise vertical support means 27. The vertical support means 27 comprise essentially a fixation plate 28 that is configured to be fixed to the respective side members 3, 4 and a cantilevered portion 29 extending cantilevered with respect to the fixation plate 28.

In particular, the fixation plate 28 may be fixed to the respective side member 3, 4 and, in particular, defines a plurality of holes to housed threaded means for fixing the latter to the side member 3, 4. The fixation plate 28 is laterally adjacent to the fixation portions 8, 23 of the transversal plates 7, i.e. it is laterally imposed in contact over these latter.

In detail, each housing 6 comprises at least a pair of front and rear vertical support means 27 that are placed, as described, in contact with a corresponding transversal plate 7. Preferably, the inner housings 6 comprises four vertical support means 27 while the outer housings 6 comprises only two vertical support means 27.

Advantageously, each vertical support means 27 is aligned on transversal direction with the other vertical support means 27, i.e. each row of housings 6 comprises two linear arrangements of vertical support means 27.

The support systems 5 defines a plurality of connections points X', X' to connect the battery modules 2 to the chassis 1 so that each battery module 2 is carried independently to the other, i.e. the weight of one battery module 2 does not lies on another battery module 2.

In particular, a first connection point X' is defined by a pin 31 carried by cantilevered portions 29 of each vertical support means 27. Such pin 31 may be inserted into a respective housing/hole realized on battery module 2 to vertically support this latter, in particular on a flanged portion 32 extending cantilevered from battery module 2. More preferably, pin 31 may comprise a threaded portion to allow the mounting of a nut to fix the battery module 2 to the vertical support means 27.

A second connection point X'' is defined by a hole 33 realized preferably on the main plate 9 in the corner between the bottom and vertical portions 10'', 10' of the coupling portion 10. The hole 2 is configured to allow the passage of a connection means for fixing the battery module 2 to the external transversal plate 7. In particular, the connection means may be realized as a threaded element, e.g. a screw. More preferably, the connection means may connect the hole 33 to a flanged portion 34 extending cantilevered from battery module 2.

The operation of a suspended support structure 5 according to the invention is the following, in particular making reference to figure 3. During the movement of the vehicle the battery modules

2 moves due to accelerations of the vehicle and to their own weight. The vertical and transversal translational forces are supported by first and second connection points X', X'' that couple the battery module 2 to the transversal walls 7a and to the vertical support means 27.

Possible torque acting about pin 31 of the vertical support means 27 due to own weight of the battery modules are supported by stabilizer bar 12 that connects together the external battery modules that are coupled by only two vertical support means 27. Indeed internal battery modules 2, being supported by four vertical support means 27 are equilibrated against all torques.

In view of the foregoing, the advantages of the suspended support structure 5 according to the invention are apparent.

Thanks to the proposed suspended support structure 5, all heavy modules, i.e. battery modules 2, are carried one independent by the other on the suspended support structure 5, i.e. the weight of one element not act on another one. Therefore, the force stresses acting on the support brackets are reduced and therefore external lateral battery modules can be carried with standard brackets.

The presence of the stabilizer bar allows to compensate torque acting between the lateral heavy modules therefore further reducing the stresses to side members and support brackets. In this way, the useful life of the suspended support structure is increased.

Moreover, the proposed suspended support structure 5 is particularly compact and allows to provide support points to heavy modules without increasing the lateral encumbrance of the vehicle or without reducing useful space within the chassis 1.

It is clear that modifications can be made to the described suspended support structure 5 which do not extend beyond the scope of protection defined by the claims. For example, the stabilizer bar 12 may have a different cross section, such as transversal walls 7a, 7b.

Furthermore, first, second and third connection points may be realized by different mechanical couplings, i.e. comprising holes, pins or shape couplings.

Moreover, coupling of the stabilizer bar via connections 13 may be realized with different typologies of movable connections or hinges.

Clearly, it is possible to use the suspended support structure 5 for supporting a different matrix of heavy modules, e.g. a two rows of three battery modules or a four rows of three battery modules.

Furthermore, as already described, the battery modules may be substituted by other heavy modules such as tanks.

Claims

1.- Heavy vehicle comprising a chassis (1) provided with a pair of side members (3, 4) extending along a longitudinal axis (A) of said vehicle and a plurality of heavy modules (2) said vehicle comprising a suspended support structure (5) for supporting said heavy modules (2), said suspended support structure (5) being fixedly carried by said side members (3, 4) and comprising a plurality of transversal walls (7a, 7b) extending transversally with respect to said side members (3, 4) and fixedly carried by this latter, said transversal walls (7a, 7b) and said side members

(3, 4) delimiting at least a row of housings (6) transversally to said longitudinal direction, said suspended support structure (5) defining a plurality of connection points (C', X'') realized in said transversal walls (7a) and/or on said side members (3, 4) for securing said heavy modules (2) to said support structure (5) and configured to support forces acting between said suspended support structure (5) and said heavy modules (2), said suspended support structure (5) comprising a stabilizer bar (12) configured to connect together said transversal walls (7) defining said plurality of connection points (C'', X" '), said stabilizer bar (12) configured to support torques acting between said suspended support structure (5) and said heavy modules (2), wherein each row of housing (6) is longitudinally delimited by a pair of external transversal walls (7a) extending from said side members (3, 4) transversally towards the environment, wherein said external transversal walls (7a) defines at least part of said plurality of connection points (C' ), said connection points (C'') comprising at least a hole (33) configured to allow the fixing of one heavy module (2) to said external transversal wall (7a), wherein said external transversal wall (7a) comprises a fixation portion (8) configured to be fixed to the side member (3, 4), a main plate (9) extending from said fixing portion (8) and a coupling portion (10) extending on opposite part of said fixation portion (8) on at least part of the perimeter of said main plate (9), said coupling portion defining said connection points (C''), wherein said stabilizer bar (12) is coupled between said coupling portions (10) of said external transversal walls (7a) and comprises a central portion (12a) and a pair of extremity portions (12b), said extremity portions (12b) being connected to said coupling portion (10) via movable connections (13).

2.- Vehicle according to claim 1, wherein said stabilizer bar (12) connects together said external transversal walls (7a) underneath said side members (3, 4).

3.- Vehicle according to claim 1 or 2, wherein said movable connection (13) comprises a hinge configured to rotate about an axis (B) parallel to said longitudinal axis (A).

4.- Vehicle according to any of the preceding claims, wherein said central portion (12a) has a T-shaped cross- section.

5.- Vehicle according to any of said preceding claims, wherein one among said fixation points (C', C' ) comprise vertical support means (27), said vertical support means (27) comprises a fixation portion (28) configured to be fixed to said side member (3, 4) and a cantilevered portion (29) extending from said fixation portion (28), said cantilevered portion defining a pin (31) configured to cooperate with one heavy module(2).

6.- Vehicle according to claim 5, wherein said fixation portion (8) is interposed between said vertical support means (27) and said side member (3, 4).

7.- Vehicle according to claim 6, wherein said suspended support structure (5) comprises inner transversal walls (7b) extending between said side members (3, 4), said inner transversal walls (7b) comprising a pair of coupling portions (23) and an intermediate portion (24), said intermediate portion (24) being collinear to said main plate (9) of said external transversal walls (7a) and delimiting axially one of said row of housings (6).

8.- Vehicle according to claim 7 wherein said coupling portion (23) is interposed between said vertical support means (27) and said side member (3, 4).

9.- Vehicle according to claims 7 or 8, wherein said vehicle comprises a front and a rear cross members (21, 22), at least one of said front and rear cross members (21, 22) being placed in linear correspondence to said external transversal walls (7a) and delimiting axially one of said row of housings (6).

10.- Vehicle according to any of the preceding claims, comprising a plurality of row, each axially adjacent along said longitudinal axis (A).

11.- Vehicle according to any of the preceding claims, wherein said heavy module is an electric battery module (2).