Whole vehicle layout structure of hydrogen fuel electric light truck

Abstract

The invention provides a hydrogen fuel electric light truck whole truck structure. The hydrogen fuel electric light truck whole truck structure comprises a cab, a container, a truck frame, a hydraulic tail plate system, a hydrogen system, an electric system, a cooling system and an air brake system. The hydraulic tail plate system comprises a hydraulic tail plate, a hydraulic tail plate oil original tank, a hydraulic tail plate controller and a hydraulic tail plate cross beam; the hydrogen system comprises a hydrogen fuel electric pile, a left hydrogen storage tank, a right hydrogen storage tank, an air inlet air filter and an exhaust silencer; the power system comprises a battery pack, an all-in-one unit, a DCDC, a DCAC, a PTC, a hydrogen stack high-voltage box, a battery high-voltage box, a charging port and a low-voltage power supply unit; the cooling system comprises a high-pressure radiator, a low-pressure radiator, a low-pressure radiator water replenishing tank, a high-pressure radiator water replenishing tank, an air conditioner condenser, an air conditioner electric compressor and an integrated kettle; the air brake system comprises an inflating pump, a drying tank, a lower air cylinder, an upper air cylinder, a front axle and an electric drive axle. The layout of the whole truck can be optimized, so that the hydrogen fuel electric light truck can be compatible with an air brake and a hydraulic tail plate.

Description

Technical Field

[0001] The present invention relates to the automotive field, and in particular to a layout structure of a hydrogen fuel electric light truck. Background Art

[0002] With the technological advancement of hydrogen fuel cells and related systems, an increasing number of OEMs are actively participating in the development of light, medium, and heavy-duty hydrogen fuel cell trucks. Light trucks, as the mainstay of urban logistics, are limited to six meters in length, allowing them to maneuver easily on city roads. As logistics vehicles, they feature hydraulic tailgates, which reduce the labor intensity of manual loading and unloading, and are therefore in high demand. Furthermore, air brakes, a more reliable braking method than hydraulic brakes, are increasingly being incorporated into light trucks, moving from medium and heavy trucks to medium and heavy trucks for safety reasons. Hydrogen fuel cell trucks require the addition of a hydrogen fuel system while retaining the components required by traditional electric vehicles. The hydrogen storage system, in particular, takes up a significant amount of space. Light trucks face the most challenging space constraints, and to maintain the limited cargo box size, the current mainstream solution is to switch the hydrogen tank from a rear-mounted design to a side-mounted design.

[0003] However, some models lack space for hydraulic tailgates, and some models that can be equipped with hydraulic tailgates only have hydraulic brakes, leaving no room for air brakes. In-depth research and optimization of the vehicle layout are urgently needed to ensure that hydrogen fuel cell electric light trucks can be equipped with both hydraulic tailgates and air brakes, while also making the overall layout more compact and safer. Summary of the Invention

[0004] In view of the defects in the prior art, the purpose of the present invention is to provide a hydrogen fuel electric light truck vehicle layout structure, aiming to optimize the vehicle layout so that the hydrogen fuel electric light truck can be compatible with air brakes and hydraulic tailgate.

[0005] In order to achieve the above-mentioned object of the invention, the present invention adopts the following technical solution:

[0006] Provide a hydrogen fuel cell electric light truck complete vehicle layout structure, including cab, cargo container, frame, hydraulic tailgate system, hydrogen system, electrical system, cooling system, and air brake system;

[0007] The cab is arranged at the front end of the frame; the container is arranged behind the cab and above the frame;

[0008] The hydraulic tail lift system includes a hydraulic tail lift, a hydraulic tail lift oil tank, a hydraulic tail lift controller, and a hydraulic tail lift crossbeam. The hydraulic tail lift is fixedly connected to the longitudinal beam at the rear end of the vehicle frame and abuts against the container. The hydraulic tail lift crossbeam is arranged under the vehicle frame. The hydraulic tail lift oil tank is arranged on the right side of the rear end of the vehicle frame and behind the rear wheel. The hydraulic tail lift controller is fixed under the container.

[0009] The hydrogen system includes a hydrogen fuel cell stack, a left hydrogen storage tank, a right hydrogen storage tank, an air intake filter, and an exhaust muffler; the hydrogen fuel cell stack is arranged at the front of the vehicle frame, below the cab, and above the front axle; the left hydrogen storage tank and the right hydrogen storage tank are arranged on both sides of the vehicle frame, between the front wheels and the rear wheels; the air intake filter is arranged on the right side of the vehicle frame, behind the front wheels; the exhaust muffler is connected to the hydrogen fuel cell stack and extends outward to the outside of the vehicle frame;

[0010] The electrical system includes a battery pack, an all-in-one, a DC / DC converter, a DC / AC converter, a PTC converter, and a hydrogen stack high-voltage box stacked on the inner side of the mid-section of the vehicle frame. The electrical system also includes a battery high-voltage box, a charging port, and a low-voltage power supply unit. The battery high-voltage box is used to distribute power to the all-in-one, the charging port is connected to the battery high-voltage box, and the low-voltage power supply unit is used to power electrical appliances inside the cab and components that require 24V voltage to wake up.

[0011] When the vehicle starts, the battery pack supplies power to the electric drive axle and provides the hydrogen fuel cell stack with the power required for its startup. After the hydrogen fuel cell stack runs smoothly, it generates electricity for the electric drive axle, and the excess power is used to charge the battery pack. When the hydrogen fuel cell stack cannot meet the power requirements of the electric drive axle, the battery pack provides additional power.

[0012] The cooling system includes a high-pressure radiator, a low-pressure radiator, a low-pressure radiator water tank, a high-pressure radiator water tank, an air-conditioning condenser, an air-conditioning electric compressor, and an integrated water kettle; the air-conditioning condenser is connected to the air-conditioning electric compressor to cool the interior of the cab through refrigerant; the high-pressure radiator is arranged on the front inner side of the frame, in front of the hydrogen fuel cell stack, and below the cab, and is driven by high-voltage AC power provided by the DCAC; the low-pressure radiator is arranged obliquely on the rear inner side of the frame, and is replenished by the low-pressure radiator water tank, and is distributed through the integrated water kettle to the electric drive axle, all-in-one, battery pack, DCAC, hydrogen stack high-pressure tank, and DCDC heat dissipation; the high-pressure radiator water tank is connected to the hydrogen fuel cell stack and the high-pressure radiator through pipelines;

[0013] The air brake system includes an air pump, a drying tank, a lower air reservoir, an upper air reservoir, a front axle and an electric drive axle; the air pump is arranged on the inner side of the middle part of the frame, and is connected to the air intake filter through a pipeline to absorb external air. The drying tank is connected to the air pump to receive the high-pressure gas provided by the air pump; the lower air reservoir is arranged below the rear end crossbeam of the frame, and the upper air reservoir is arranged above the lower wing surface on the inner side of the rear end of the frame; the front axle and the electric drive axle are provided with air brake devices, which receive air delivered by the lower air reservoir and the upper air reservoir to provide air brake assistance for the entire vehicle.

[0014] Preferably, the electrical system further comprises mounting brackets 2 and 3 fixed to the lower wing surface of the vehicle frame, which can be disassembled and assembled in the vertical direction; the all-in-one is fixed to mounting bracket 3, and the DCDC, DCAC, PTC, and hydrogen stack high-voltage box are integrated and arranged on mounting bracket 2; the battery high-voltage box is placed between the battery pack and the electric drive axle, above the frame crossbeam; the interfaces of the DCDC, PTC, and DCAC are located near the edge of the battery high-voltage box; the charging port is arranged behind the rear wheel and in front of the hydraulic tailgate oil source tank;

[0015] The low-voltage power supply unit includes battery 1, battery 2, and battery 3; battery 1 is arranged on the left side of the frame, above the exhaust muffler, and is used to power the electrical appliances inside the cab; battery 2 and battery 3 are arranged in series on the right side of the frame, below the air intake filter, to power components that require 24V voltage power supply and wake-up.

[0016] Preferably, the air conditioning condenser is arranged on the right front side of the frame, in front of the front wheel, and below the cab, and is arranged at a certain angle to the ventral surface of the frame; the low-pressure radiator is placed obliquely in the middle position between the lower air reservoir and the upper air reservoir;

[0017] The high-pressure radiator water tank and the low-pressure radiator water tank are arranged between the cab and the cargo box, symmetrically on both sides of the frame; below the high-pressure radiator water tank is battery one, and below that is the exhaust muffler; below the low-pressure radiator water tank is the air intake filter, and below that are batteries two and three; the high-pressure radiator water tank and the low-pressure radiator water tank are located in the space in front of the left and right air tanks respectively;

[0018] The integrated kettle and battery pack are arranged on the same level and located in front of the battery pack, behind the air conditioning electric compressor and air pump, and above the frame crossbar.

[0019] Preferably, it also includes a mounting bracket 1, a compressor suspension, an air pump suspension, and a sound insulation pad;

[0020] The mounting bracket 1 is fixed to the lower wing surface of the vehicle frame; the air-conditioning electric compressor is arranged on the mounting bracket 1 and fixed on the compressor suspension; the air pump is fixed on the mounting bracket 1 through the air pump suspension; the air pump and the air-conditioning electric compressor are arranged side by side; the air pump suspension and the compressor suspension are both provided with rubber structures; and a sound insulation pad is arranged under the cab.

[0021] Preferably, the drying tank is arranged on the left outer side of the rear end of the frame and behind the rear wheel.

[0022] Compared with the prior art, the present invention has the following beneficial effects:

[0023] 1. The present invention optimizes the overall vehicle layout so that hydrogen fuel electric light trucks can be compatible with air brakes and hydraulic tailgates, providing convenience for loading and unloading, reducing labor intensity, and taking into account the safety and reliability of vehicle braking.

[0024] 2. The present invention reserves sufficient space for hydrogen storage through a special hydrogen system layout design to improve the vehicle's endurance. At the same time, the provision of an exhaust muffler can improve the NVH performance of the entire vehicle, while avoiding occupying the space inside the frame and effectively utilizing the space.

[0025] 3. The present invention adopts a special electrical system structure design, in which the electrical components and battery packs are stacked and integrated, to optimize the position of each component, effectively utilize the space inside the frame, provide the necessary convenience for repair and maintenance, and save a lot of space for the entire vehicle. The invention can further adopt the use of combined brackets to reduce weight and save costs.

[0026] 4. This invention utilizes a unique cooling system design that incorporates a high-pressure radiator, improving its cooling capacity. This eliminates the need for multiple radiators in conventional hydrogen fuel cell vehicles, freeing up space throughout the vehicle and increasing the feasibility of hydrogen fuel cell electric light trucks being compatible with air brakes and hydraulic tailgates. The low-pressure radiator is combined with an integrated water bottle, which distributes coolant to various electrical appliances, improving cooling efficiency, reducing the number of cooling lines, and lowering costs. The stacked, integrated layout of the water tank and other components efficiently utilizes the space between the cab and cargo box, further increasing the feasibility of hydrogen fuel cell electric light trucks being compatible with air brakes and hydraulic tailgates.

[0027] 5. This invention utilizes a unique air brake system design, with the dryer tank and air reservoir positioned rearward, at a distance from the air pump. The metal pipes ventilating between them are long enough to cool the high-pressure air. Furthermore, the proximity of the air reservoir and dryer tank reduces the need for connecting pipes. The simultaneous placement of two air reservoirs meets the vehicle's air braking requirements. The smaller lower reservoir is positioned below the frame without affecting the vehicle's departure angle, while the larger upper reservoir is positioned above the lower wing of the frame, freeing up space for the hydraulic tailgate crossbeam and providing a safe space for the low-pressure radiator to be protected from both front and rear.

[0028] 6. The present invention further combines CAE analysis of vehicle vibration patterns to optimize the layout of key components, significantly reducing the strength requirements of the bracket, reducing the cost of design and components, and at the same time extending the service life of vibration components. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Other features, objects and advantages of the present invention will become more apparent upon reading the detailed description of non-limiting embodiments with reference to the following drawings:

[0030] Figure 1Schematic diagram of the left side view of the entire structure of the hydrogen fuel electric light truck described in the embodiment;

[0031] Figure 2 Schematic top view of the entire structure of the hydrogen fuel electric light truck described in the embodiment;

[0032] Figure 3 Schematic diagram of the structure of mounting bracket 1, mounting bracket 2, and mounting bracket 3 in the whole vehicle structure of the hydrogen fuel electric light truck described in the embodiment;

[0033] Figure 4 Schematic diagram of the sound insulation pad in the whole vehicle structure of the hydrogen fuel electric light truck described in the embodiment;

[0034] Figure 5 Schematic diagram of the low-pressure radiator structure in the hydrogen fuel electric light truck structure described in the embodiment;

[0035] Figure 6 Schematic diagram of CAE analysis described in the examples.

[0036] The figure shows:

[0037] DETAILED DESCRIPTION

[0038] To make the objectives, technical solutions, and advantages of the embodiments of the present application more clear, the technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Generally, the components of the embodiments of the present application described and shown in the drawings herein can be arranged and designed in various different configurations.

[0039] Therefore, the following detailed description of the embodiments of the present application provided in the accompanying drawings is not intended to limit the scope of the present application for protection, but merely represents selected embodiments of the present application. All other embodiments obtained by persons of ordinary skill in the art based on the embodiments in the present application without making any creative efforts shall fall within the scope of protection of the present application.

[0040] It should be noted that similar reference numerals and letters denote similar items in the following figures. Therefore, once an item is defined in one figure, it does not require further definition or explanation in subsequent figures. Furthermore, all directional designations (such as up, down, left, right, front, back, bottom, etc.) in this application are intended only to explain the relative positional relationships and movement of components in a specific posture (as shown in the figures). If the specific posture changes, the directional designations will also change accordingly.

[0041] Example

[0042] This embodiment provides a hydrogen fuel cell electric light truck complete vehicle structure, which makes the overall layout of the hydrogen fuel cell electric light truck more rational and safer, allowing the light truck model to accommodate a hydrogen system, electrical system, cooling system, air brake system, and hydraulic tailgate within a limited space, while reducing vehicle weight and cost. The hydrogen fuel cell electric light truck complete vehicle structure provided in this embodiment includes a cab 1, a cargo container 2, a frame 26, and a hydraulic tailgate system, a hydrogen system, an electrical system, a cooling system, and an air brake system.

[0043] like Figure 1 As shown, the cab 1 is arranged at the front end of the frame 26 , and the container 2 is arranged behind the cab 1 and above the frame 26 .

[0044] like Figure 1 、 Figure 2 As shown, the hydraulic tail lift system includes a hydraulic tail lift 3, a hydraulic tail lift oil tank 301, a hydraulic tail lift controller 302, and a hydraulic tail lift crossbeam 303. This system facilitates loading and unloading of goods by logistics vehicles and reduces manual labor. Specifically, the hydraulic tail lift 3 is fixedly connected to the left and right longitudinal beams at the rear end of the vehicle frame 26, resting against the cargo container 2. The hydraulic tail lift crossbeam 303 is positioned below the vehicle frame 26, while the hydraulic tail lift oil tank 301 is located on the right side of the rear end of the vehicle frame 26, behind the rear wheel 2101. The hydraulic tail lift controller 302 is located behind the hydraulic tail lift 3 and is fixed below the cargo container 2, near the outer edge of the container 2 but not exposed.

[0045] like Figure 1 、 Figure 2 As shown, the specific structure of the hydrogen system includes a hydrogen fuel cell stack 10, a left hydrogen storage tank 401, a right hydrogen storage tank 402, an intake air filter 8, and an exhaust muffler 6. The hydrogen fuel cell stack 10 generates electricity through an electrochemical reaction between hydrogen and oxygen. It is located at the front of the vehicle frame 26, below the cab 1, and above the front axle 22, where the original fuel light truck engine would be located. The hydrogen required by the hydrogen fuel cell stack 10 is provided by the left and right hydrogen storage tanks 401, 402, which are symmetrically arranged on either side of the vehicle frame 26, between the front and rear wheels 2201, 2101. The required oxygen is provided by the intake air filter 8, which is located on the right side of the vehicle frame 26 and behind the front wheels 2201, drawing in outside air. The exhaust muffler 6 is connected to the lower left corner of the hydrogen fuel cell stack 10 and extends outward to the outside of the vehicle frame. It is fixed behind the front wheel and in front of the hydrogen storage tank. Since the hydrogen stack does not emit polluting exhaust gas, no exhaust after-treatment device is set. Adding a muffler can eliminate the noise generated by the emission and improve the comfort of the driver and passengers.

[0046] like Figure 1 、 Figure 2 、 Figure 4As shown, the specific structure of the electrical system includes a battery pack 9, an all-in-one 11, a DCDC 15, a DCAC 17, a PTC 16, a hydrogen stack high-voltage box 18, a charging port 19, a battery high-voltage box 13, a second mounting bracket 24, a third mounting bracket 25, and a low-voltage power supply unit.

[0047] The battery pack 9, all-in-one unit 11, DC-DC converter 15, positive temperature coefficient heater 16, DC-AC converter 17, and hydrogen stack high-pressure tank 18 are stacked on the inner side of the midsection of the vehicle frame, with the battery pack 9 placed on the top layer. Below them are the all-in-one unit 11, DC-DC converter 15 (DC-DC converter), positive temperature coefficient heater 16, DC-AC converter 17 (DC-AC converter), and hydrogen stack high-pressure tank 18. The all-in-one unit 11 is secured to mounting bracket 3 25, which is fixed to the lower wing surface of the vehicle frame 26. The DC-DC converter 15, DC-AC converter 17, PTC 16, and hydrogen stack high-pressure tank 18 are integrated on mounting bracket 24, which is fixed to the lower wing surface of the vehicle frame 26. The DC-DC converter 15, PTC 16, and DC-AC converter 17 are located near the edge of the battery high-pressure tank 13. The ports are located on the side surface, which is close to the edge of the battery high-pressure tank 13. This allows access to the ports by reaching over the high-pressure tank, facilitating subsequent maintenance. The hydrogen stack high-pressure tank 18 is placed in the middle of the frame 26, leaving room for side operations. Mounting bracket 24 and mounting bracket 3 25 are fixed to the lower wing surface of the frame 26 and can be disassembled and assembled in the vertical direction.

[0048] The charging port 19 is arranged behind the rear wheel 2101 and in front of the hydraulic tailgate oil source box 301, and is connected to the battery high-voltage box 13 to charge the battery pack 9. Since it is at the rear end of the vehicle, the convenience of charging can be improved.

[0049] The low-voltage power supply unit includes three 12V batteries, namely battery 1 701, battery 2 702, and battery 3 (not shown in the figure). Battery 1 701 is arranged on the left side of the frame 26, above the exhaust muffler 6, to power the electrical appliances inside the cab 1; battery 2 702 and battery 3 (not shown in the figure) are arranged on the right side of the frame 26, below the air intake filter 8, and are connected in series to form a 24V power supply to power components that require 24V voltage power supply and wake-up.

[0050] The battery high-voltage box 13 is placed between the battery pack 9 and the electric drive axle 21, above the crossbeam of the frame 26, and is placed close to the battery pack 9 to reduce the length of the high-voltage wire and reduce costs.

[0051] The electric energy generated by the electrical system is supplied to the electric drive axle 21 for driving the entire vehicle. The overall electrical operation logic of the vehicle is as follows: when the vehicle starts, the battery pack 9 provides power to the electric drive axle 21 and provides the hydrogen fuel cell stack 10 with the power required for its startup. After the hydrogen fuel cell stack 10 runs smoothly, the hydrogen fuel cell stack 10 generates electricity for the electric drive axle 21, and the excess power is used to charge the battery pack 9. If the vehicle needs to accelerate, go uphill, or other working conditions, and the electric drive axle 21 requires more power, the hydrogen fuel cell stack 10 will provide full power and the battery pack 9 will supplement it to meet the needs of the entire vehicle. Specifically:

[0052] The electricity generated by the hydrogen fuel cell stack 10 is transmitted to the hydrogen stack high-voltage tank 18, which distributes it to the all-in-one 11. The all-in-one 11 then controls the electric drive axle 21 to drive the vehicle. The hydrogen stack high-voltage tank 18 also distributes some of the electricity to the DCAC 17, which converts it into AC power to power the high-voltage radiator 1201.

[0053] The all-in-one 11 distributes power to the DC-DC converter 15, which converts the voltage to 24V to charge Battery 2 702 and Battery 3 (not shown). Furthermore, the all-in-one 11 also integrates a DC-DC converter that converts the voltage to 12V, directly charging Battery 1 701 to ensure sufficient battery power. Furthermore, the all-in-one 11 directly powers the PTC 16, the air conditioning electric compressor 1402, and the air pump 504 to operate these components. The PTC 16 provides warm air to the cab 1, the air conditioning electric compressor 1402 and the air conditioning condenser 1401 work together to provide cool air inside the cab 1, and the air pump 504 provides high-pressure air to the air brake system. Finally, the all-in-one 11 is connected to the battery high-voltage box 13 via a high-voltage wiring harness, which in turn is connected to the battery pack 9. When the vehicle is operating smoothly, excess power generated by the hydrogen stack can be transferred through the battery high-voltage box 13 to charge the battery pack 9, avoiding waste of the hydrogen stack's generated power.

[0054] The battery high-voltage box 13 is connected to an external charging port 19, which can directly charge the battery pack 9 from the external power grid, replenishing the power during the logistics vehicle's rest period, which can reduce the user's usage cost.

[0055] The electrical system provided by this embodiment has various electrical components and battery packs stacked and integrated. By optimizing the position of each component, it effectively utilizes the space inside the frame and provides the necessary convenience for repair and maintenance, saving a large amount of space for the entire vehicle. At the same time, due to the close location, the length of each high-voltage wiring harness is reduced, significantly reducing costs. The use of combined brackets can reduce weight and save costs. Each bracket can be disassembled from the top and bottom, providing convenience for after-sales maintenance. At the same time, the integrated bracket layout saves bracket data, reducing the weight and cost of the entire vehicle.

[0056] like Figure 1 、 Figure 2、 Figure 3 、 Figure 4 、 Figure 5 As shown, the specific structure of the cooling system includes a high-pressure radiator 1201, a low-pressure radiator 1202, a low-pressure radiator water supply tank 1203, a high-pressure radiator water supply tank 1204, an air-conditioning condenser 1401, an air-conditioning electric compressor 1402, a compressor suspension 1403, a mounting bracket 23, and an integrated kettle 12.

[0057] The air conditioning condenser 1401 is used to cool the interior of the cab 1. It is located on the right front side of the vehicle frame 26, in front of the front wheel 2201, and below the cab 1. It is connected to the air conditioning electric compressor 1402 and uses refrigerant to cool the interior of the cab 1, enhancing passenger comfort. The air conditioning condenser 1401 is positioned at an angle to the underside of the vehicle frame 26. This tilted placement maximizes the area within the limited space enclosed by the cab 1, frame 26, and front wheel 2201, ensuring greater airflow.

[0058] The air conditioning electric compressor 1402 is used to cooperate with the air conditioning electric compressor 1402 to reduce the temperature in the cab 1. It is arranged in the middle of the vehicle frame 26 and at the rear of the cab 1. It is fixed to the mounting bracket 23 via the compressor mount 1403. At the same time, the mounting bracket 23 also fixes the air pump 504 via the air pump mount 505. The air conditioning electric compressor 1402 and the air pump 504 are both high-speed rotating components. The air pump mount 505 and the compressor mount 1403 are both equipped with rubber structures to reduce the vibration generated by the air conditioning electric compressor 1402 and the air pump 504 during operation, thereby reducing the higher strength requirements of the mounting bracket 23. In order to reduce the noise impact of the above two components on the cab occupants, a large-area sound insulation pad 20 is set under the cab 1 to improve the comfort of the occupants. The air pump 504 and the air-conditioning electric compressor 1402 are arranged side by side and fixed to the lower wing surface of the frame 26 through an installation bracket 23 to meet the requirements of subsequent maintenance and disassembly. At the same time, if the two vibration sources are arranged in different positions, it is necessary to consider the strength of the two brackets and their respective impact on the surrounding noise, so they are arranged on the same bracket to improve design efficiency.

[0059] The cooling system further includes a high-pressure radiator 1201, a low-pressure radiator 1202, a high-pressure radiator water supply tank 1204, and a low-pressure radiator water supply tank 1203.

[0060] The high-voltage radiator 1201 is arranged on the inner side of the front end of the frame 26, in front of the hydrogen fuel cell stack 10 (hydrogen stack), and below the cab 1; the high-voltage radiator 1201 is driven by high-voltage alternating current provided by DCAC17, and has higher power than the existing low-voltage DC radiator, and is used to cool the hydrogen fuel cell stack 10 with a large heat dissipation demand.

[0061] like Figure 3 As shown, low-pressure radiator 1202 is positioned inside the rear end of frame 26, tilted, with lower and upper air reservoirs 501 and 502 positioned in front and behind, respectively, to provide comprehensive protection. Low-pressure radiator 1202 is positioned inside the rear end of frame 26, tilted between lower and upper air reservoirs 501 and 502. This ensures a good departure angle for the vehicle while also providing protection from bumps on the road, thanks to the air reservoir in front.

[0062] The high-pressure radiator water tank 1204 and the low-pressure radiator water tank 1203 are positioned between the cab 1 and the cargo container 2, symmetrically arranged on either side of the vehicle frame 26. Below the high-pressure radiator water tank 1204 is battery 1 701, and below that is the exhaust muffler 6. Similarly, below the low-pressure radiator water tank 1203 is the intake air filter 8, and below that are battery 2 702 and battery 3 (not shown). The high-pressure radiator water tank 1204 and the low-pressure radiator water tank 1203 are located in the space in front of the left and right air tanks 401 and 402, respectively. They are stacked in a top-to-bottom relationship with the batteries and exhaust muffler 6, significantly saving chassis space and enhancing the feasibility of hydrogen-fueled electric light trucks with air brakes and hydraulic tailgates.

[0063] The high-pressure radiator water replenishing tank 1204 is connected to the hydrogen fuel cell stack 10 and the high-pressure radiator 1201 through pipelines. The high-pressure radiator 1201 is dedicated to cooling and dissipating heat of the hydrogen fuel cell stack 10 and is replenished with water by the high-pressure radiator water replenishing tank 1204.

[0064] The low-pressure radiator 1202 is distributed through the integrated water bottle 12 to provide cooling for the electric drive axle 21, all-in-one 11, battery pack 9, DCAC17, hydrogen stack high-pressure box 18, and DCDC15. The water is replenished by the low-pressure radiator water supply tank 1203. The distribution through the integrated water bottle 12 can reduce the number of cooling pipes. The cooling water can be heat-exchanged inside the integrated water bottle 12. The water pump inside the integrated water bottle 12 can control the flow of each water channel, improve heat dissipation efficiency, and reduce costs. The integrated water bottle 12 and the battery pack 9 are arranged on the same layer and are located in front of the battery pack 9, behind the air-conditioning electric compressor 1402 and the air pump 504, and above the crossbeam of the frame 26. This arrangement provides all-round protection for the integrated water bottle 12, improving safety. The surrounding components provide 360-degree protection for the integrated water bottle made of plastic.

[0065] The cooling system incorporates a high-pressure radiator 1201, enhancing its cooling capacity. This eliminates the need for multiple radiators in conventional hydrogen fuel cell vehicles, freeing up space throughout the vehicle and increasing the feasibility of hydrogen fuel cell electric light trucks with air brakes and hydraulic tailgates. The low-pressure radiator 1202, combined with the integrated water bottle 12, distributes coolant to various electrical appliances, improving cooling efficiency, reducing the number of cooling lines, and lowering costs. The stacked, integrated layout of the water tanks behind the left and right front wheels and other components efficiently utilizes the space between the cab and cargo box, further enhancing the feasibility of hydrogen fuel cell electric light trucks with air brakes and hydraulic tailgates.

[0066] like Figure 1 、 Figure 2 、 Figure 3 、 Figure 4 、 Figure 5 As shown, the specific structure of the air brake system includes an air pump 504, an air pump suspension 505, a drying tank 503, a lower air reservoir 501, an upper air reservoir 502, a front axle 22 and an electric drive axle 21.

[0067] The lower air reservoir 501 is arranged below the rear end crossbeam of the frame 26, and the upper air reservoir 502 is arranged on the inner side of the rear end of the frame 26, above the lower wing surface. The line connecting the upper air reservoir 502 and the center line of the lower air reservoir 501 forms a certain angle with the horizontal plane. The space formed inside can be provided to the low-pressure radiator 1202.

[0068] The drying tank is arranged on the left outer side of the rear end of the frame 26 and behind the rear wheel 2101, and receives the high-pressure gas provided by the air pump 504. A ventilation pipe is connected between the drying tank and the air pump 504, and the length of the pipe can meet the demand for cooling the high-pressure air. The drying tank 503 is close to the upper air storage cylinder 502 and the lower air storage cylinder 501, which can reduce the length of the interconnected pipes and reduce costs.

[0069] The air pump 504 is arranged on the inner side of the middle part of the frame 26, and is fixed on the mounting bracket 23 through the air pump suspension 505, close to the air intake filter 8 and connected to it through a pipeline to facilitate the absorption of external air.

[0070] The air brake devices on the front axle 22 and the electric drive axle 21 receive air delivered by the lower air reservoir 501 and the upper air reservoir 502 to provide air brake assistance for the entire vehicle, reduce braking distance, and improve vehicle safety.

[0071] The air brake system of this embodiment places the air pump in front, close to the air intake, so that it can draw air filtered by the air filter from the air intake pipe nearby, reducing the length of the pipeline and saving costs. The drying tank and the air reservoir are arranged at a certain distance from the air pump at the rear, and the metal pipe for ventilation in between is long enough to cool the high-pressure air, replacing the spiral pipe setting of conventional models. The air reservoir and the drying tank are close to each other, which can save connecting pipes. At the same time, two air reservoirs can meet the air braking needs of the entire vehicle. The small lower air reservoir is arranged under the frame and will not affect the departure angle of the entire vehicle. The large upper air reservoir is arranged above the lower wing surface of the frame, making room for the hydraulic tailgate crossbeam, and at the same time providing a safe space for front and rear protection for the low-pressure radiator.

[0072] Through CAE theoretical research and actual vehicle test data accumulation and analysis, for light truck models with a frame, the vibration of the whole vehicle tends to be strong at both ends and weak in the middle. Figure 6 . The range with the smallest middle vibration is set as area one, that is, within 300mm behind the rear mounting support of the front leaf spring on the frame, and the rest of the middle range is set as area two, that is, within 1700mm from the rear of area one to the front mounting support of the rear leaf spring on the frame. In the structure provided in this embodiment, the vibration data of the light truck was analyzed during the vehicle layout research, and the high-speed air-conditioning compressor and air brake pump were arranged within the range of area one. The vibration in the three directions of X\Y\Z is the smallest within the range of the vehicle, which can significantly reduce the strength requirements of the bracket, reduce the cost of design and components, and extend the service life of the vibrating components. The remaining high-value and fragile electrical components are arranged within the range of area two using a stacked integration solution, which can reduce the vibration acceleration of the components, increase the service life, improve the electrical safety of the vehicle, and reduce the user's cost of use. These electrical components include: battery pack 9, hydrogen stack high-voltage box 18, DCDC15, DCAC16, all-in-one 11, battery high-voltage box 13, PTC16. In the hydrogen system, two gas tanks are arranged on both sides of the frame 26, spanning areas 1 and 2 where the vehicle vibration is minimal, improving the safety of hydrogen use in the vehicle, reducing the strength requirements of the hydrogen tank bracket, and reducing the cost of design and components.

[0073] The above describes the specific embodiments of the present invention. Based on the above description, relevant personnel can make various changes and modifications without departing from the scope of the technical concept of this invention.

Claims

1. A hydrogen fuel electric light truck complete vehicle structure, characterized in that: Including cab, cargo container, frame, hydraulic tailgate system, hydrogen system, electrical system, cooling system, and air brake system; The cab is arranged at the front end of the frame; the container is arranged behind the cab and above the frame; The hydraulic tail lift system includes a hydraulic tail lift, a hydraulic tail lift oil tank, a hydraulic tail lift controller, and a hydraulic tail lift crossbeam. The hydraulic tail lift is fixedly connected to the longitudinal beam at the rear end of the vehicle frame and abuts against the container. The hydraulic tail lift crossbeam is arranged under the vehicle frame. The hydraulic tail lift oil tank is arranged on the right side of the rear end of the vehicle frame and behind the rear wheel. The hydraulic tail lift controller is fixed under the container. The hydrogen system includes a hydrogen fuel cell stack, a left hydrogen storage tank, a right hydrogen storage tank, an air intake filter, and an exhaust muffler; the hydrogen fuel cell stack is arranged at the front of the vehicle frame, below the cab, and above the front axle; the left hydrogen storage tank and the right hydrogen storage tank are arranged on both sides of the vehicle frame, between the front wheels and the rear wheels; the air intake filter is arranged on the right side of the vehicle frame, behind the front wheels; the exhaust muffler is connected to the hydrogen fuel cell stack and extends outward to the outside of the vehicle frame; The electrical system includes a battery pack, an all-in-one, a DC / DC converter, a DC / AC converter, a PTC converter, and a hydrogen stack high-voltage box stacked on the inner side of the mid-section of the vehicle frame. The electrical system also includes a battery high-voltage box, a charging port, and a low-voltage power supply unit. The battery high-voltage box is used to distribute power to the all-in-one, the charging port is connected to the battery high-voltage box, and the low-voltage power supply unit is used to power electrical appliances inside the cab and components that require 24V voltage to wake up. When the vehicle starts, the battery pack supplies power to the electric drive axle and provides the hydrogen fuel cell stack with the power required for its startup. After the hydrogen fuel cell stack runs smoothly, it generates electricity for the electric drive axle, and the excess power is used to charge the battery pack. When the hydrogen fuel cell stack cannot meet the power requirements of the electric drive axle, the battery pack provides additional power. The cooling system includes a high-pressure radiator, a low-pressure radiator, a low-pressure radiator water tank, a high-pressure radiator water tank, an air-conditioning condenser, an air-conditioning electric compressor, and an integrated water kettle; the air-conditioning condenser is connected to the air-conditioning electric compressor to cool the interior of the cab through refrigerant; the high-pressure radiator is arranged on the front inner side of the frame, in front of the hydrogen fuel cell stack, and below the cab, and is driven by high-voltage AC power provided by the DCAC; the low-pressure radiator is arranged obliquely on the rear inner side of the frame, and is replenished by the low-pressure radiator water tank, and is distributed through the integrated water kettle to the electric drive axle, all-in-one, battery pack, DCAC, hydrogen stack high-pressure tank, and DCDC heat dissipation; the high-pressure radiator water tank is connected to the hydrogen fuel cell stack and the high-pressure radiator through pipelines; The air brake system includes an air pump, a drying tank, a lower air reservoir, an upper air reservoir, a front axle and an electric drive axle; the air pump is arranged on the inner side of the middle part of the frame, and is connected to the air intake filter through a pipeline to absorb external air. The drying tank is connected to the air pump to receive the high-pressure gas provided by the air pump; the lower air reservoir is arranged below the rear end crossbeam of the frame, and the upper air reservoir is arranged above the lower wing surface on the inner side of the rear end of the frame; the front axle and the electric drive axle are provided with air brake devices, which receive air delivered by the lower air reservoir and the upper air reservoir to provide air brake assistance for the entire vehicle.

2. The hydrogen fuel electric light truck structure according to claim 1, characterized in that: The electrical system also includes mounting brackets 2 and 3 fixed to the lower wing surface of the vehicle frame, which can be disassembled and assembled in the vertical direction; the all-in-one is fixed to mounting bracket 3, and the DCDC, DCAC, PTC, and hydrogen stack high-voltage box are integrated and arranged on mounting bracket 2; the battery high-voltage box is placed between the battery pack and the electric drive axle, above the frame crossbeam; the interfaces of the DCDC, PTC, and DCAC are located near the edge of the battery high-voltage box; the charging port is located behind the rear wheel and in front of the hydraulic tailgate oil source tank; The low-voltage power supply unit includes battery 1, battery 2, and battery 3; battery 1 is arranged on the left side of the frame, above the exhaust muffler, and is used to power the electrical appliances inside the cab; battery 2 and battery 3 are arranged in series on the right side of the frame, below the air intake filter, to power components that require 24V voltage power supply and wake-up.

3. The hydrogen fuel electric light truck structure according to claim 2, characterized in that: The air conditioning condenser is located on the right front side of the vehicle frame, in front of the front wheel and below the cab, with a certain angle to the underside of the vehicle frame. The low-pressure radiator is placed at an angle between the lower and upper air reservoirs. The high-pressure radiator water tank and the low-pressure radiator water tank are arranged between the cab and the cargo box, symmetrically on both sides of the frame; below the high-pressure radiator water tank is battery one, and below that is the exhaust muffler; below the low-pressure radiator water tank is the air intake filter, and below that are batteries two and three; the high-pressure radiator water tank and the low-pressure radiator water tank are located in the space in front of the left and right air tanks respectively; The integrated kettle and battery pack are arranged on the same level and located in front of the battery pack, behind the air conditioning electric compressor and air pump, and above the frame crossbar.

4. The hydrogen fuel electric light truck structure according to claim 1, characterized in that: Also includes mounting bracket 1, compressor mount, air pump mount, and sound insulation pad; The mounting bracket 1 is fixed to the lower wing surface of the vehicle frame; the air-conditioning electric compressor is arranged on the mounting bracket 1 and fixed on the compressor suspension; the air pump is fixed on the mounting bracket 1 through the air pump suspension; the air pump and the air-conditioning electric compressor are arranged side by side; the air pump suspension and the compressor suspension are both provided with rubber structures; and a sound insulation pad is arranged under the cab.

5. The hydrogen fuel electric light truck structure according to claim 1, characterized in that: The drying tank is arranged on the left outer side of the rear end of the frame and behind the rear wheel.

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