A modular hydrogen fuel cell heavy truck arrangement

Abstract

The application relates to the technical field of new energy commercial vehicle chassis, and particularly discloses a vehicle with a modular hydrogen fuel cell heavy truck arrangement structure, which comprises a power system, an energy storage module system and a driving system. The power system is arranged with a flattened high-low temperature cooling integrated sub-module, a fuel cell engine and an accessory module, and an air conditioner and waste heat recovery system integrated sub-module. The energy storage system is arranged with a side-hung hydrogen bottle sub-module, a rear hydrogen bottle sub-module, a multi-in-one controller integrated sub-module, a high-voltage accessory integrated sub-module, a low-voltage accessory integrated sub-module and a power battery sub-module. The driving system adopts an electric drive axle module integrated scheme, and the electric drive axle module is integrated with a driving motor, a motor controller, a transmission and a drive axle. The functions and structures of the sub-module systems are highly integrated, and the integrated and lightweight levels are high. The integrated arrangement of the modules is not restricted by market conditions, vehicle types, cab types and the like, and the universality and interchangeability levels of the components are greatly improved.

Description

Technical Field

[0001] This invention relates to the field of new energy commercial vehicle chassis technology, specifically to a vehicle with a modular hydrogen fuel cell heavy-duty truck layout structure. Background Technology

[0002] Existing technology 1:

[0003] The chassis accessories of this new energy hydrogen fuel cell vehicle mainly include: fuel cell engine, intake and exhaust system, high temperature cooling module, low temperature cooling module, power battery, hydrogen supply system, multi-integrated controller, BMS, electric power steering pump, electric air compressor, low-voltage battery, electric air conditioning compressor, electric drive axle, etc.

[0004] The fuel cell engine is located inside the vehicle frame. The high-temperature and low-temperature cooling modules are arranged separately. The high-temperature cooling system is located at the front of the fuel cell engine, and the low-temperature cooling module is located at the rear of the power battery on the outer side of the left longitudinal beam of the vehicle frame. The intake system is located at the rear of the fuel cell, and the exhaust system is located at the bottom of the fuel cell engine.

[0005] The power battery adopts a frame structure and is arranged on both sides of the vehicle frame. The hydrogen supply system is located behind the rear of the cab. The integrated cooling unit, multi-function controller, and electric air compressor are stacked inside the vehicle frame at the rear of the fuel cell engine. The BMS and low-voltage battery are respectively mounted on the left and right longitudinal beams of the vehicle frame. The electric power steering pump is located above the left longitudinal beam of the vehicle frame, and the electric air conditioning compressor is located above the right longitudinal beam of the vehicle frame. See details for the specific layout. Figure 1 and Figure 2 .

[0006] Disadvantages of existing technology 1:

[0007] 1) Loose Layout: The BMS, electric oil pump, and electric air conditioning compressor high-voltage accessories are located on the left and right sides of the front end of the frame longitudinal beams, the electric air compressor is located on the lower inner side of the middle of the frame, and the power battery is located on both sides of the frame longitudinal beams. The layout of high-voltage components and the power battery is not compact, increasing the length of the high-voltage wiring harnesses from the BMS to the multi-function controller and power battery, from the multi-function controller to the main drive high-voltage harness of the electric drive axle, and from the multi-function controller to the auxiliary drive high-voltage harnesses such as the electric air compressor, electric air conditioning compressor, and electric oil pump. Furthermore, the high-voltage wiring harnesses are messy and aesthetically unappealing. There is significant wasted space between the electric air compressor and the electric drive axle, and the side-mounted power battery limits the expandability of the hydrogen supply system, failing to meet the layout requirements for long-range driving conditions.

[0008] 2) Poor reliability: The high and low voltage interfaces of components such as the multi-in-one controller, electric drive axle, and BMS are not oriented in the correct direction, and the high and low voltage wiring harness connections are not smooth. High voltage accessories such as BMS, electric oil pump, and electric air conditioning compressor, as well as the power battery, are arranged on the left and right sides of the vehicle frame longitudinal beams, and the high and low voltage wiring harnesses cross each other, which easily leads to electromagnetic compatibility problems and poor overall vehicle reliability.

[0009] 3) Poor maintainability: The multi-in-one integrated controller, BMS, and integrated cooling unit are stacked in three layers (top, middle, and bottom). When repairing the battery cooling module, it is necessary to remove the multi-in-one integrated controller and bracket, high and low voltage wiring harnesses, and cooling pipes. The electric air compressor is located at the bottom inside the frame, making air filter replacement and maintenance difficult.

[0010] 4) Low assembly efficiency: The chassis accessories such as the multi-in-one integrated controller, electric air compressor, electric air conditioning compressor, electric power steering pump, BMS, and low-voltage battery are scattered and fixed by mounting brackets. The chassis is heavy and the chassis assembly process is poor.

[0011] Existing technology 2:

[0012] The chassis components of this new energy hydrogen fuel cell vehicle differ from the first technical solution in the following ways: The electric drive assembly is changed to a drive motor + transmission + mechanical axle. The motor controller (MCU), drive motor, and transmission are located inside the longitudinal beams of the frame. The fuel cell engine is located inside the frame, with high-temperature and low-temperature cooling modules arranged separately. The high-temperature cooling system is located at the front of the fuel cell engine, and the low-temperature cooling module is located at the rear of the hydrogen supply system in the middle of the frame. The motor controller (MCU) is located on the outer side of the right longitudinal beam of the frame, in front of the low-voltage battery. The multi-function controller, electric air compressor, and integrated cooling unit are stacked inside the frame. See details for the specific layout. Figure 3 and Figure 4 .

[0013] Disadvantages of existing technology 2:

[0014] 1) Poor chassis aesthetics: The MCU is located on the outside of the right longitudinal beam of the chassis, the BMS on the outside of the left longitudinal beam, the electric air conditioning compressor, electric power steering pump, and power battery on the outside of the left and right longitudinal beams, and the multi-function controller and electric air compressor on the inside of the chassis. The high-voltage wiring harness is complex, with increased intersections, and the MCU connection to the high-voltage wiring harness is aesthetically unappealing. The cryogenic cooling module is located at the rear of the hydrogen supply system, and the cooling pipes and low-voltage wiring harness layout affects the overall aesthetics of the chassis.

[0015] 2) Poor compatibility of the upper structure: The low-temperature cooling module protrudes from the rear of the hydrogen supply system, reducing the turning radius of the vehicle and making it poorly compatible with different types of semi-trailers with different front suspensions.

[0016] Therefore, there is an urgent need to design a modular hydrogen fuel cell heavy-duty truck layout structure to solve the problems of scattered accessory layout, poor reliability, poor maintainability, low space utilization, and poor aesthetics of existing hydrogen fuel cell chassis. Summary of the Invention

[0017] To address the problems existing in the prior art, the purpose of this invention is to provide a vehicle with a modular hydrogen fuel cell heavy-duty truck layout structure, which is a modular layout scheme for hydrogen fuel cell heavy-duty trucks that combines sub-modules, integrates the system, and separates high and low pressure.

[0018] The technical solution adopted by this invention to solve its technical problem is: a vehicle with a modular hydrogen fuel cell heavy-duty truck layout structure, including a power system, an energy storage module system, and a drive system. The power system is arranged with a flat high and low temperature cooling integrated sub-module, a fuel cell engine and accessory module, and an air conditioning and waste heat recovery system integrated sub-module. The energy storage system is arranged with a side-mounted hydrogen tank module, a rear-mounted hydrogen tank module, a multi-in-one controller integrated sub-module, a high-voltage accessory integrated module, a low-voltage accessory integrated module, and a power battery sub-module. The drive system adopts an electric drive axle module integration scheme, in which the electric drive axle module integrates a drive motor, a motor controller, a transmission, and a drive axle.

[0019] The high-voltage accessory integration submodule is located on the left side of the longitudinal beam of the frame assembly, and the low-voltage accessory integration submodule is located on the right side of the longitudinal beam of the frame assembly. The multi-in-one controller integration submodule, power battery submodule and electric drive axle module are located in the middle of the frame. The positions and directions of the high-voltage wiring harness, low-voltage wiring harness, water interface and air interface of the multi-in-one controller integration submodule, motor controller, drive axle and integrated auxiliary machine are planned. The high-voltage wiring harness interface is generally arranged to the left or rear, and the low-voltage wiring harness and pipeline interface are generally arranged to the right.

[0020] Specifically, the flattened high and low temperature cooling integrated submodule is arranged at the front of the fuel cell engine and front-end accessories. The flattened high and low temperature cooling integrated submodule integrates the fuel cell cooling unit, the low temperature cooling unit, the air conditioner and battery condenser, and the high-pressure fan. The fuel cell cooling unit, the low temperature cooling unit, the air conditioner and battery condenser, and the high-pressure fan are arranged in layers and stacked. The air conditioner and battery condenser, the low temperature radiator, the high temperature radiator, and the high-pressure large-diameter electric fan are arranged in front and behind. The low temperature radiator and the air conditioner and battery condenser are arranged as a single heat dissipation core layer, and the high temperature radiator is arranged as a single heat dissipation core layer stacked at the rear of the low temperature radiator and the air conditioner and battery condenser. The high-pressure large-diameter fan is stacked at the rear of the high temperature radiator.

[0021] Specifically, the air conditioning and waste heat recovery system integrated submodule is located at the rear of the fuel cell engine. The air conditioning and waste heat recovery system integrated submodule integrates an electric air conditioning compressor, a water heating PTC, a water-to-water heat exchanger, a water pump, a gas-liquid separator, and a transition bracket. The electric air conditioning compressor and waste heat recovery accessories are arranged in upper and lower layers. The electric air conditioning compressor is located at the bottom of the transition bracket, and the water heating PTC, water-to-water heat exchanger, water pump, and gas-liquid separator are located on the upper layer of the transition bracket. The air conditioning and waste heat recovery system integrated submodule adopts a U-shaped frame structure and is bolted to the left and right longitudinal beams of the vehicle frame assembly through lifting lugs.

[0022] Specifically, the multi-in-one controller integrated sub-module includes a multi-in-one controller, an air tank 1, and an integrated bracket. The multi-in-one controller and the two air tanks 1 are arranged vertically on top of each other. The multi-in-one controller is arranged at the top with the upper flange of the frame assembly aligned with it. The multi-in-one controller is mounted on the integrated bracket, and the integrated bracket is fixed to the left and right longitudinal beams of the frame assembly by bolts.

[0023] Specifically, the high-pressure accessory integration submodule includes an integrated bracket, an integrated auxiliary machine, and a BMS. The integrated auxiliary machine includes an electric air compressor and an electric steering oil pump. The integrated auxiliary machine and the BMS are installed on the integrated bracket. The BMS is located above the integrated auxiliary machine. The integrated bracket is bolted to the left longitudinal beam of the vehicle frame assembly using an integral frame. The interfaces of the BMS and the integrated auxiliary machine meet the requirements for high and low pressure separation.

[0024] Specifically, the low-voltage accessory integrated submodule includes an integrated bracket two, a 24V lithium battery, a battery cooling unit, a water-heating PTC, and an expansion tank. The battery cooling unit is installed on the integrated bracket two, and the water-heating PTC is integrated and fixed on the outside of the battery cooling unit. The 24V lithium battery and the expansion tank are located above the battery cooling unit and installed on the integrated bracket two. The integrated bracket two is fixed to the right longitudinal beam of the vehicle frame assembly by bolts. The battery cooling unit, the 24V lithium battery, and the expansion tank meet the requirements for separate arrangement of high and low voltage wiring harnesses and pipelines.

[0025] Specifically, the side-mounted hydrogen cylinder module integrates a hydrogen cylinder, a side-mounted bottom guard plate, a contoured bracket, a second gas storage tank, and a second transition bracket. The hydrogen cylinder is bolted to the vehicle frame assembly via a pull strap through the semi-circular contoured bracket. The second gas storage tank is installed on the back of the contoured bracket through the second transition bracket, and the side-mounted bottom guard plate is installed at the bottom of the hydrogen cylinder.

[0026] Specifically, the drive axle of the electric drive bridge module is equipped with dual motors, and the high-voltage interface and low-voltage interface of the electric drive bridge module are respectively reserved with front and rear space of the drive axle for separate wiring of the high-voltage interface and low-voltage interface.

[0027] Specifically, the power battery submodule includes a battery frame and a power battery. The power battery is installed inside the battery frame, and the battery frame is bolted to the left and right longitudinal beams of the vehicle frame assembly on both sides.

[0028] The present invention has the following beneficial effects:

[0029] This invention relates to a modular hydrogen fuel cell heavy-duty truck layout structure that integrates and lightweights vehicles. It integrates and arranges sub-modules such as a flattened high / low temperature cooling system, air conditioning and waste heat recovery system, multi-functional controller and gas storage tank, high-pressure accessories, low-pressure accessories, power battery and frame, side-mounted hydrogen tank and gas storage tank, rear-mounted hydrogen tank, and electric drive axle, eliminating the need for separate fixed supports for each module. Simultaneously, it integrates the functions of the electric air compressor and electric steering pump, the drive motor, transmission, and motor controller, and utilizes low-pressure lithium batteries, achieving a high degree of functional and structural integration. This reduces the number of components by ≥20% and the weight by over 200 kg.

[0030] This invention improves vehicle reliability through a modular hydrogen fuel cell heavy-duty truck layout structure: It defines a "high-voltage and low-voltage separation" principle, with the high-voltage wiring harness arranged on the left longitudinal beam and the low-voltage wiring harness on the right longitudinal beam. The high-voltage accessory submodule is located on the left side of the frame longitudinal beam, and the low-voltage accessory submodule is located on the right side. The multi-functional controller, power battery, and electric drive axle (integrated MCU) submodule are located in the middle of the frame. The high-voltage accessory submodule and multi-functional controller submodule are arranged in a close, flat layout, significantly shortening the high-voltage wiring harness length and preventing electromagnetic interference from the high-voltage harness to the low-voltage harness. Furthermore, to enhance wiring harness reliability, dedicated wiring harness slots and mounting brackets are designed, further improving chassis reliability.

[0031] This invention presents a modular hydrogen fuel cell heavy-duty truck layout structure that is highly versatile and scalable. It defines the wiring harness and piping interface layout and routing for high and low pressure accessory controllers, achieving standardized interface applications that can be directly extended to all vehicle models. The integrated layout of each sub-module is not limited by market segmentation, vehicle model, or cab type, and can be matched and combined according to requirements. Sub-modules can be matched with cooling modules for different heat dissipation needs, multi-in-one integrated controllers (four-in-one, five-in-one, etc.), low-voltage batteries of different capacities, integrated auxiliary machines of different power levels, power batteries of different capacities, and hydrogen supply systems of different capacities, ensuring the universality and interchangeability of each component. The system's internal and inter-system functional and structural integration results in a compact chassis layout and improved vehicle space utilization. For long-range requirements, a combination of side-mounted hydrogen tank modules and rear single-row or rear double-row hydrogen tank modules can be used to meet the market demand for long-range vehicles. The sub-modules offer strong scalability.

[0032] The modular hydrogen fuel cell heavy-duty truck layout designed in this invention improves vehicle maintenance convenience: the system functions and structure are integrated, and the high and low voltage accessories are arranged in a staggered manner, taking into account the inspection and maintenance needs of high and low voltage accessories such as the multi-in-one integrated controller, integrated auxiliary machine, 24V lithium battery, and BMS. This enables rapid inspection and maintenance, reduces the frequency of disassembly and repair, and avoids the problem of removing other components due to stacked layout.

[0033] The modular hydrogen fuel cell heavy-duty truck layout designed in this invention improves the vehicle assembly process: sub-modules such as high-pressure accessories, low-pressure accessories, air conditioning and waste heat recovery, and side-mounted hydrogen cylinders can all be assembled off-line, breaking the current process of assembling each component separately in new energy vehicles and improving the overall vehicle assembly efficiency.

[0034] The modular hydrogen fuel cell heavy-duty truck layout designed in this invention improves vehicle aesthetics: the combination of sub-modules, the integration of system structure, the compact chassis layout, the separation of high and low pressure and pipelines, the smooth pipeline layout, the avoidance of wire harness crossing, the rear hydrogen supply module adopts an integrated protective cover, the side protection is designed on both sides of the chassis, the top is equipped with a fully covered operating platform, and the bottom protection is arranged, resulting in a neat and beautiful chassis. Attached Figure Description

[0035] Figure 1 This is a top view illustrating the layout of existing technology.

[0036] Figure 2 This is a schematic side view of the existing technology layout.

[0037] Figure 3 This is a top view of the existing technology arrangement.

[0038] Figure 4 This is a side view of the existing technology arrangement.

[0039] Figure 5 This is a structural schematic diagram of the overall layout scheme of the modular hydrogen fuel cell heavy-duty truck chassis.

[0040] Figure 6 This is a top view illustrating the chassis layout of a modular hydrogen fuel cell heavy-duty truck.

[0041] Figure 7 This is a schematic diagram of the structure of a flattened high and low temperature cooling integrated submodule.

[0042] Figure 8 This is a structural diagram of the integrated submodule for air conditioning and waste heat recovery.

[0043] Figure 9 This is a schematic diagram of the structure of the all-in-one controller integrated submodule.

[0044] Figure 10This is a schematic diagram of the side-mounted hydrogen cylinder module.

[0045] Figure 11 This is a structural diagram of the low-voltage accessory integrated submodule.

[0046] Figure 12 This is a structural diagram of the high-voltage accessory integrated submodule.

[0047] Figure 13 This is a structural diagram of the power battery submodule.

[0048] In the diagram: 1- Flat high and low temperature cooling integrated sub-module, 101- Fuel cell engine, 102- Front-end accessories, 103- High pressure fan, 104- Fuel cell cooling unit, 105- Low temperature cooling unit, 106- Air conditioner and battery condenser;

[0049] 2-Vehicle frame assembly; 3-Fuel cell engine and accessory modules;

[0050] 4-Integrated sub-module for air conditioning and waste heat recovery, 401-Gas-liquid separator, 402-Water heating PTC, 403-Water-to-water heat exchanger, 404-Water pump, 405-Electric air conditioning compressor, 406-Transition bracket one, 407-Hanging lug;

[0051] 5-High voltage accessory integrated submodule, 501-Integrated bracket one, 502-Integrated auxiliary machine, 503-BMS;

[0052] 6-Multi-in-one controller integrated sub-module, 601-Multi-in-one controller, 602-Gas storage tank one, 603-Integrated bracket;

[0053] 7-Power battery sub-module, 701-Battery frame, 702-Power battery;

[0054] 8-Side-mounted hydrogen cylinder module, 801-Hydrogen cylinder, 802-Side-mounted bottom guard plate, 803-Contouring bracket, 804-Gas storage tank II, 805-Transition bracket II;

[0055] 9-Low-voltage accessory integrated submodule, 901-Integrated bracket II, 902-24V lithium battery, 903-Battery cooling unit, 904-Water heating PTC, 905-Expansion tank;

[0056] 10 - Rear hydrogen cylinder module; 11 - Electric drive bridge module. Detailed Implementation

[0057] The technical solutions of the embodiments of the present invention will be described in further detail below with reference to the accompanying drawings. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0058] Key Terminology Definitions and Explanations:

[0059] 1. Power Module: Located at the bottom of the cab of the new energy commercial vehicle, it is a power accessory module composed of components such as fuel cell engine and accessories, flat high and low temperature heat dissipation sub-module, air conditioning and waste heat recovery system integration module.

[0060] 2. Flat high and low temperature cooling submodule: It consists of components such as high temperature heat sink, low temperature heat sink, high voltage electric fan and air conditioning condenser. The high temperature heat sink is used to cool the fuel cell stack. The low temperature heat sink is mainly used to cool the fuel cell low temperature system, motor, motor controller, multi-in-one controller, high voltage fan motor and controller, low voltage DC / DC and other motor and electronic control systems. The air conditioning condenser is mainly used to cool the cab air conditioner and power battery.

[0061] 3. Fuel cell waste heat recovery system: The system adopts a C2C and water-heated PTC system, which uses the high-temperature waste heat of the fuel cell and the water-heated PTC to heat the power battery and the cab.

[0062] 4. Air conditioning and waste heat recovery integrated sub-module: an air conditioning accessory module that integrates and arranges air conditioning compressors, water heating PTC, water-to-water heat exchangers, water pumps, gas-liquid separators and other accessories in a layered manner.

[0063] like Figures 5-13 As shown, a modular hydrogen fuel cell heavy-duty truck layout includes a power system, an energy storage module system, and a drive system. The power system includes a flat high and low temperature cooling integrated submodule 1, a fuel cell engine and accessory module 3, and an air conditioning and waste heat recovery system integrated submodule 4. The energy storage system includes a side-mounted hydrogen tank module 8, a rear-mounted hydrogen tank module 10, a multi-function controller integrated submodule 6, a high-pressure accessory integrated submodule 5, a low-pressure accessory integrated module 9, and a power battery submodule 7. The drive system adopts an electric drive axle module 11 integrated scheme, which integrates a drive motor, a motor controller (MCU), a transmission, and a drive axle.

[0064] The high-voltage accessory integration submodule 5 is located on the left side of the longitudinal beam of the frame assembly 2, and the low-voltage accessory integration submodule 9 is located on the right side of the longitudinal beam of the frame assembly 2. The multi-in-one controller integration submodule 6, the power battery submodule 7, and the electric drive axle module 11 are located in the middle of the frame assembly 2. The positions and directions of the high-voltage wiring harness, low-voltage wiring harness, water interface, and air interface of the multi-in-one controller integration submodule 6, the motor controller, the drive axle, and the integrated auxiliary machine are planned. The high-voltage wiring harness interface is generally arranged to the left or rear, and the low-voltage wiring harness and pipeline interface are generally arranged to the right.

[0065] like Figure 7 As shown, the flattened high and low temperature cooling integrated submodule 1 is arranged at the front of the fuel cell engine 101 and the front-end accessory 102. The flattened high and low temperature cooling integrated submodule 1 integrates the fuel cell cooling unit 104, the low temperature cooling unit 105, the air conditioner and battery condenser 106, and the high-pressure fan 103. The fuel cell cooling unit 104, the low temperature cooling unit 105, the air conditioner and battery condenser 106, and the high-pressure fan 103 are arranged in layers and stacked. The air conditioner and battery condenser 106, the low temperature radiator, the high temperature radiator, and the high-pressure large-diameter electric fan are arranged sequentially front and rear. The low temperature radiator and the air conditioner and battery condenser are arranged as a single heat dissipation core layer, and the high temperature radiator is arranged as a single heat dissipation core layer stacked at the rear of the low temperature radiator and the air conditioner and battery condenser 106. The high-pressure large-diameter fan is stacked at the rear of the high temperature radiator. The flattened high and low temperature cooling integrated submodule 1 is fixed to the front-end accessory of the vehicle frame using a suspension structure bolt. This is not limited to this arrangement. For example, the arrangement of condensers and low-temperature radiators may vary depending on the structural changes of the cab front cover and bumper, the cooling performance requirements of fuel cell and pure electric vehicles under different operating conditions, the number and specifications of high and low pressure fans may vary, and the arrangement of a three-layer core (condenser + low-temperature radiator + high-temperature radiator) + high-pressure large-diameter fan and the upper and lower layered arrangement of high-temperature cooling and low-temperature cooling are also protected by this claim.

[0066] like Figure 8 As shown, the air conditioning and waste heat recovery system integration submodule 4 is located at the rear of the fuel cell engine 101. The air conditioning and waste heat recovery system integration submodule 4 integrates an electric air conditioning compressor 405, a water heating PTC 402, a water-to-water heat exchanger 403, a water pump 404, a gas-liquid separator 401, and a transition bracket 406. The electric air conditioning compressor 405 and the waste heat recovery accessories are arranged in upper and lower layers. The electric air conditioning compressor 405 is arranged at the bottom of the transition bracket 406, and the water heating PTC 402, the water-to-water heat exchanger 403, the water pump 404, and the gas-liquid separator 401 are arranged on the upper layer of the transition bracket 406. The air conditioning and waste heat recovery system integration submodule 4 adopts a U-shaped frame structure and is bolted to the left and right longitudinal beams of the vehicle frame assembly 2 through the suspension lugs 407.

[0067] like Figure 9 As shown, the multi-function controller integrated submodule 6 includes a multi-function controller 601, two air tanks 602, and an integrated bracket 603. The multi-function controller 601 and the two air tanks 602 are arranged vertically and horizontally. The multi-function controller 601 is aligned with the upper flange of the frame assembly 2 and mounted on the integrated bracket 603, which is bolted to the left and right longitudinal beams of the frame assembly 2. For fuel cell engines 100 of different lengths, the chassis wheelbase is lengthened, and the air conditioning and waste heat recovery submodule, the multi-function controller 601, and the air tank integrated submodule are moved rearward to meet the layout requirements of different vehicle models. The multi-function integrated controller 601 defines the position and direction of the high-pressure interface by defining the main drive and auxiliary drive interface layout and high-pressure flow direction, achieving high and low pressure separation.

[0068] like Figure 12 As shown, the high-pressure accessory integrated submodule 5 includes an integrated bracket 501, an integrated auxiliary machine 502, and a BMS 503. The integrated auxiliary machine 502 includes an electric air compressor and an electric steering oil pump. The integrated auxiliary machine 502 and the BMS 503 are mounted on the integrated bracket 501, with the BMS 503 located above the integrated auxiliary machine 502. The integrated bracket 501 is fixed to the left longitudinal beam of the frame assembly 2 with an integral frame bolt. The interfaces of the BMS 503 and the integrated auxiliary machine 502 meet the requirements for high and low pressure separation.

[0069] like Figure 11 As shown, the low-voltage accessory integrated submodule 9 includes an integrated bracket 2 901, a 24V lithium battery 902, a battery cooling unit 903, a water heater PTC 904, and an expansion tank 905. The battery cooling unit 903 is mounted on the integrated bracket 2 901. The water heater PTC 904 is integrated and fixed on the outside of the battery cooling unit 903. The 24V lithium battery 902 and the expansion tank 905 are located above the battery cooling unit 903 and mounted on the integrated bracket 2 901. The integrated bracket 2 901 is fixed to the right longitudinal beam of the frame assembly 2 by bolts. The battery cooling unit 903, the 24V lithium battery 902, and the expansion tank 905 meet the requirements for separate arrangement of high and low voltage wiring harnesses and pipelines.

[0070] like Figure 10As shown, the side-mounted hydrogen cylinder module 8 integrates a hydrogen cylinder 801, a side-mounted bottom guard plate 802, a contoured bracket 803, a second gas storage tank 804, and a second transition bracket 805. The hydrogen cylinder 801 is bolted to the vehicle frame assembly 2 via a strap through the semi-circular contoured bracket 803. The second gas storage tank 804 is mounted on the back of the contoured bracket 803 via the second transition bracket 805. The side-mounted bottom guard plate 802 is installed at the bottom of the hydrogen cylinder 801. By arranging single or double rows of hydrogen cylinder modules behind the cab, the driving range can be increased without increasing the overall wheelbase. Simultaneously, using a chassis without side mounting, and separately arranging single or double rows of hydrogen storage modules and combinations of hydrogen cylinder numbers behind the cab to meet different transport distance requirements, also falls under the protection of this claim.

[0071] The drive bridge of the electric drive bridge module 11 is equipped with dual motors. The electric drive bridge module 11 is integrated with the MCU. The high voltage interface and low voltage interface of the electric drive bridge module 11 are reserved with front and rear space of the drive bridge respectively for separate routing of high voltage interface and low voltage interface.

[0072] like Figure 13 As shown, the power battery submodule 7 includes a battery frame 701 and a power battery 702. The power battery 702 is installed inside the battery frame 701. The battery frame 701 is bolted to the left and right longitudinal beams of the vehicle frame assembly 2 on both sides.

[0073] This invention provides a modular hydrogen fuel cell heavy-duty truck layout structure and vehicle, including modular system combination, sub-module combination, system and structure integration, and a chassis layout scheme with separate high and low voltage wiring harnesses. It forward-plans the functional and layout requirements of hydrogen fuel cell chassis components, adhering to the principles of universality and platform-based layout. It adopts a layout scheme of integrated high and low temperature cooling modules, integrated high-pressure accessory modules, integrated low-pressure accessory modules, and integrated air conditioning and waste heat recovery modules to achieve a modular chassis layout. The layout positions of the power battery, hydrogen supply system, high-pressure controller, and low-pressure accessory are planned to maximize chassis space utilization and allow for expandable hydrogen supply system space to meet long-range driving requirements. Simultaneously, based on the principles of separating high and low voltage components and pipelines, and the direction of high-voltage current flow, the positions and directions of interfaces such as the fuel cell engine, electric drive axle, multi-in-one controller, integrated auxiliary equipment, BMS, and high-voltage controllers and accessories, high and low voltage wiring harnesses, cooling and braking pipelines, and hydrogen refueling ports are newly defined. This achieves a high degree of integration and modularity of the chassis component layout interfaces, standardized layout of chassis high and low voltage wiring harnesses and pipelines, smooth routing, and improved overall chassis aesthetics.

[0074] 1) Layout principles: Ensure chassis versatility and minimize the correlation between chassis modules and cab components. Redefine the functions and interface locations of chassis modules, and integrate them according to the principle of proximity between the controller and its actuators. The layout of high-voltage and low-voltage controllers and wiring harnesses follows the principles of separation of high and low voltage and pipelines, and high-voltage current routing. The chassis is designed and assembled according to the principles of system integration and sub-module combination.

[0075] 2) Functional and structural integration: Considering the integrated layout, the vehicle is divided into a power system, an energy storage module system, and a drive system. The power system includes a flat high and low temperature cooling integrated sub-module 1, a fuel cell engine and accessory module 3, and an air conditioning and waste heat recovery system integrated sub-module 4. The energy storage system includes a side-mounted hydrogen tank module 8, a rear-mounted hydrogen tank module 10, a multi-function controller integrated sub-module 6, a high-voltage accessory integrated sub-module 5, a low-voltage accessory integrated sub-module 9, and a power battery sub-module 7. The drive system adopts an electric drive axle module 11 integrated solution, which integrates the drive motor, motor controller, transmission, and drive axle.

[0076] 3) High Integration and Modularization: The flat high and low temperature cooling integrated submodule 1 is integrated and fixed to the front end of the frame using two suspension brackets; the high-pressure accessory submodule 5 is integrated and fixed to the left longitudinal beam of the frame using an integral bracket; the low-pressure accessory submodule 9 is integrated and fixed to the right longitudinal beam of the frame using an integral bracket; the air conditioning and waste heat recovery system submodule 4 is fixed to the left and right longitudinal beams of the frame using an integrated bracket; and the side-mounted hydrogen tank module 8, with its integrated gas storage tank, is fixed to the longitudinal beam of the frame using an integral bracket. The high degree of submodule integration allows for matching and combination with different vehicle models, significantly reducing the variety and quantity of parts, lowering chassis weight, and reducing development costs.

[0077] 4) High and low voltage separation: Define the arrangement of high voltage wiring harness on the left longitudinal beam and low voltage wiring harness on the right longitudinal beam. The multi-in-one controller integrated module 6 is placed in front of the power battery sub-module. The high voltage accessory sub-module 5 is arranged on the left side of the frame longitudinal beam and the low voltage accessory sub-module 9 is arranged on the right side of the frame longitudinal beam to achieve separation of high and low voltage wiring harnesses. This avoids electromagnetic compatibility issues from the design source and prevents low voltage from being interfered with by the high voltage system during operation.

[0078] 5) Scalability: The power battery sub-module 7 is centrally located. For short-distance transportation, the side-mounted hydrogen tank modules are arranged on both sides of the chassis longitudinal beams. For medium and long-distance transportation, the chassis wheelbase and accessory arrangement remain unchanged. Based on the side-mounted hydrogen tank module 8, the rear-mounted hydrogen tank module 10 is arranged behind the cab. Single-row and double-row hydrogen tank arrangement options are available according to the range requirements to meet the range requirements of different market segments and improve the scalability of the chassis.

[0079] 6) Smooth Piping Layout: Based on the high-voltage current flow direction and the requirements for wiring harnesses and pipe layout, the positions and directions of high and low voltage and cooling interfaces of chassis modules such as BMS, multi-function controller 601, high-voltage accessories, and electric drive axle have been newly planned, resulting in a more rational and smooth layout and routing of high and low voltage wiring harnesses and pipes. At the same time, the multi-function controller sub-module, high-voltage accessory sub-module (BMS and integrated auxiliary equipment), and power battery sub-module are arranged nearby, significantly shortening the length of high-voltage wiring harnesses and effectively reducing the overall vehicle cost.

[0080] 7) Modular assembly: Based on the sub-module integrated layout scheme, the flat high and low temperature cooling integrated sub-module 1, air conditioning and waste heat recovery system sub-module 4, high pressure accessory sub-module 5, low pressure accessory sub-module 9, side-mounted hydrogen tank module 8, multi-in-one controller sub-module 6, rear hydrogen tank module 10, power battery and frame sub-module, and electric drive axle module 11 can all be assembled off the production line, breaking the current process of assembling each component separately in new energy vehicles and improving the assembly efficiency of the whole vehicle.

[0081] This invention is not limited to the above-described embodiments. Anyone should know that any structural changes made under the guidance of this invention, and any technical solutions that are the same as or similar to this invention, fall within the protection scope of this invention.

[0082] The technologies, shapes, and structures not described in detail in this invention are all known technologies.

Claims

1. A vehicle with a modular hydrogen fuel cell heavy-duty truck layout structure, characterized in that, It includes a power system, an energy storage module system, and a drive system. The power system is arranged with a flat high and low temperature cooling integrated sub-module, a fuel cell engine and accessory module, and an air conditioning and waste heat recovery system integrated sub-module. The energy storage system is arranged with a side-mounted hydrogen tank module, a rear-mounted hydrogen tank module, an all-in-one controller integrated sub-module, a high-pressure accessory integrated module, a low-pressure accessory integrated module, and a power battery sub-module. The drive system adopts an integrated electric drive axle module solution, which integrates the drive motor, motor controller, transmission and drive axle; The high-voltage accessory integration submodule is located on the left side of the longitudinal beam of the frame assembly, and the low-voltage accessory integration submodule is located on the right side of the longitudinal beam of the frame assembly. The multi-in-one controller integration submodule, power battery submodule and electric drive axle module are located in the middle of the frame. The positions and directions of the high-voltage wiring harness, low-voltage wiring harness, water interface and air interface of the multi-in-one controller integration submodule, motor controller, drive axle and integrated auxiliary machine are planned. The high-voltage wiring harness interface is generally arranged to the left or rear, and the low-voltage wiring harness and pipeline interface are generally arranged to the right.

2. The vehicle with the modular hydrogen fuel cell heavy-duty truck layout structure according to claim 1, characterized in that, The flattened high and low temperature cooling integrated submodule is arranged at the front of the fuel cell engine and front-end accessories. The flattened high and low temperature cooling integrated submodule integrates the fuel cell cooling unit, the low temperature cooling unit, the air conditioner and battery condenser, and the high pressure fan. The fuel cell cooling unit, the low temperature cooling unit, the air conditioner and battery condenser and the high pressure fan are arranged in layers and stacked. The air conditioner and battery condenser, the low temperature radiator, the high temperature radiator and the high pressure large diameter electric fan are arranged in front and behind. The low temperature radiator and the air conditioner and battery condenser are arranged in a single heat dissipation core layer, and the high temperature radiator is arranged in a single heat dissipation core layer layer, which is stacked behind the low temperature radiator and the air conditioner and battery condenser. The high pressure large diameter fan is stacked behind the high temperature radiator.

3. The vehicle with the modular hydrogen fuel cell heavy-duty truck layout structure according to claim 2, characterized in that, The air conditioning and waste heat recovery system integration submodule is located at the rear of the fuel cell engine. The air conditioning and waste heat recovery system integration submodule integrates an electric air conditioning compressor, a water heating PTC, a water-to-water heat exchanger, a water pump, a gas-liquid separator, and a transition bracket. The electric air conditioning compressor and waste heat recovery accessories are arranged in upper and lower layers. The electric air conditioning compressor is located at the bottom of the transition bracket, and the water heating PTC, water-to-water heat exchanger, water pump, and gas-liquid separator are located on the upper layer of the transition bracket. The air conditioning and waste heat recovery system integration submodule adopts a U-shaped frame structure and is bolted to the left and right longitudinal beams of the vehicle frame assembly through lifting lugs.

4. The vehicle with the modular hydrogen fuel cell heavy-duty truck layout structure according to claim 1, characterized in that, The multi-function controller integrated sub-module includes a multi-function controller, an air tank 1, and an integrated bracket. The multi-function controller and the two air tanks 1 are arranged vertically on top of each other. The multi-function controller is arranged at the top with the upper flange of the frame assembly aligned with it. The multi-function controller is mounted on the integrated bracket, which is fixed to the left and right longitudinal beams of the frame assembly by bolts.

5. The vehicle with the modular hydrogen fuel cell heavy-duty truck layout structure according to claim 1, characterized in that, The high-pressure accessory integration submodule includes an integrated bracket, an integrated auxiliary machine, and a BMS. The integrated auxiliary machine includes an electric air compressor and an electric steering oil pump. The integrated auxiliary machine and the BMS are installed on the integrated bracket. The BMS is located above the integrated auxiliary machine. The integrated bracket is bolted to the left longitudinal beam of the vehicle frame assembly using an integral frame. The interfaces of the BMS and the integrated auxiliary machine meet the requirements for high and low pressure separation.

6. The vehicle with the modular hydrogen fuel cell heavy-duty truck layout structure according to claim 1, characterized in that, The low-voltage accessory integrated submodule includes an integrated bracket two, a 24V lithium battery, a battery cooling unit, a water-heating PTC, and an expansion tank. The battery cooling unit is mounted on the integrated bracket two, and the water-heating PTC is integrated and fixed on the outside of the battery cooling unit. The 24V lithium battery and the expansion tank are located above the battery cooling unit and mounted on the integrated bracket two. The integrated bracket two is fixed to the right longitudinal beam of the vehicle frame assembly by bolts. The battery cooling unit, the 24V lithium battery, and the expansion tank meet the requirements for separate arrangement of high and low voltage wiring harnesses and pipelines.

7. The vehicle with the modular hydrogen fuel cell heavy-duty truck layout structure according to claim 1, characterized in that, The side-mounted hydrogen cylinder module integrates a hydrogen cylinder, a side-mounted bottom guard plate, a contoured bracket, a second gas storage tank, and a second transition bracket. The hydrogen cylinder is bolted to the vehicle frame assembly via a pull strap through the semi-circular contoured bracket. The second gas storage tank is installed on the back of the contoured bracket through the second transition bracket, and the side-mounted bottom guard plate is installed at the bottom of the hydrogen cylinder.

8. The vehicle with the modular hydrogen fuel cell heavy-duty truck layout structure according to claim 1, characterized in that, The electric drive bridge module has a dual-motor drive axle. The high-voltage and low-voltage interfaces of the electric drive bridge module are respectively reserved in the front and rear spaces of the drive axle for separate wiring of the high-voltage and low-voltage interfaces.

9. The vehicle with the modular hydrogen fuel cell heavy-duty truck layout structure according to claim 1, characterized in that, The power battery submodule includes a battery frame and a power battery. The power battery is installed inside the battery frame, and the battery frame is bolted to the left and right longitudinal beams of the vehicle frame assembly on both sides.

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