A heavy truck electrical accessory integrated structure and a heavy truck

Abstract

The utility model discloses a heavy truck electric accessory integrated structure and heavy truck belong to electric truck technical field, and heavy truck electric accessory integrated structure includes steering motor, heat management module, electric air compressor, power electronic unit and high voltage box, and its characterized in that: including integrated frame, steering motor, heat management module, electric air compressor, power electronic unit and high voltage box install in integrated frame, and integrated frame constructs and forms from below to the three layer mounting space of upwards, and electric air compressor installs in lower layer mounting space, and steering motor sets up in middle layer mounting space, and heat management module, power electronic unit, high voltage box set up in upper layer mounting space. This integrated structure has considered space optimization, assembly efficiency, heat dissipation performance and operation convenience, and provides a kind of efficient, reasonable, high engineering degree solution for the electric accessory arrangement of pure electric heavy truck.

Description

Technical Field

[0001] This utility model belongs to the field of electric truck technology, and in particular relates to an integrated structure for electric accessories of heavy trucks and heavy trucks. Background Technology

[0002] Electric heavy-duty trucks are a type of new energy heavy-duty truck that uses power batteries as its primary energy source and is driven by an electric drive system. They feature green and environmentally friendly characteristics such as zero emissions, low noise, and high energy efficiency, and are widely used in urban logistics, short-distance transportation, and port transshipment. Compared to traditional fuel-powered heavy-duty trucks, electric heavy-duty trucks eliminate complex mechanical structures such as engines and transmissions, resulting in lower overall maintenance costs, faster response, and more precise power control. They also possess the integrated advantages of high intelligence and compatibility with various electric accessory modules (such as electric air compressors, electric steering, and power electronics units), making them an important direction for achieving low-carbon transformation and intelligent upgrading of heavy-duty commercial vehicles.

[0003] Currently, electric heavy-duty trucks generally suffer from dispersed structures and low integration in their electrical accessory layout. Existing technologies often employ a method where various accessories, such as electric air compressors, steering motors, power electronics units, and thermal management modules, are mounted separately on different locations on the chassis using independent brackets. This results in low overall vehicle space utilization, cluttered layouts, complex wiring harnesses, and hinders optimized wiring and heat dissipation. Taking a certain 350kWh pure electric tractor as an example, this model disperses its electrical accessories, leading not only to complex assembly processes, longer operation times, and higher costs, but also increasing the difficulty of vehicle maintenance and the potential for malfunctions. Furthermore, the high-voltage box is forced to be installed inside the battery frame, occupying the effective space originally intended for battery placement. This not only reduces the energy density of the battery system but also necessitates reinforcement of the battery frame structure and material redundancy, further exacerbating space waste and structural burden. This layout method, lacking overall integrated design, struggles to meet the current development demands for high efficiency, lightweight, modularity, and ease of maintenance in electric heavy-duty trucks, and has become a significant bottleneck restricting the improvement of overall vehicle performance and engineering adaptability. Utility Model Content

[0004] To address the problems of low space utilization, complex assembly, inconvenient maintenance, and structural redundancy caused by the dispersed arrangement of electrical accessories in existing technologies, this utility model provides an integrated structure for electrical accessories of heavy-duty trucks and a heavy-duty truck.

[0005] This utility model is implemented as follows: an integrated structure for heavy-duty truck electrical accessories, including a steering motor, a thermal management module, an electric air compressor, a power electronics unit, and a high-voltage box, characterized in that: it includes an integrated frame, on which the steering motor, thermal management module, electric air compressor, power electronics unit, and high-voltage box are mounted; the integrated frame is constructed to form a three-layer mounting space from bottom to top; the electric air compressor is mounted in the lower mounting space; the steering motor is located in the middle mounting space; and the thermal management module, power electronics unit, and high-voltage box are located in the upper mounting space.

[0006] In the above technical solution, preferably, the integrated frame includes a lower frame, a middle frame, and an upper frame; the lower frame is constructed as a rectangular frame forming a lower installation space inside, the middle frame is constructed as a horizontal frame forming a middle installation space on the upper part, and the upper frame is constructed as a horizontal frame forming an upper installation space on the upper part.

[0007] In the above technical solution, preferably, the intermediate frame is fixed to the front middle part of the lower frame, and the upper frame is fixed to the upper part of the lower frame.

[0008] In the above technical solution, preferably, a diagonal brace is provided between the front part of the intermediate frame and the lower frame, and a diagonal support is provided between the upper frame and the lower frame.

[0009] This heavy-duty truck electrical accessory integration structure utilizes a unified integrated frame design to systematically and layer the steering motor, thermal management module, electric air compressor, power electronics unit, and high-voltage box within the same frame, forming a three-layer installation space layout from bottom to top. This significantly improves the integration and space utilization efficiency of the vehicle's electrical accessories. This structure offers several advantages and positive effects: First, by replacing scattered installation with centralized layout, the space occupied by the chassis is significantly reduced, freeing up space resources that were originally occupied by multiple independent brackets. Second, the modular integrated frame simplifies the assembly process, shortens assembly time, reduces labor costs, and improves production efficiency. Third, the distribution of various electrical accessories at different levels according to their functional characteristics and thermal management requirements is conducive to optimizing ventilation and heat dissipation paths, improving system stability and operational reliability. Fourth, the unified structural support enhances the structural rigidity and shock resistance of the entire vehicle, especially by setting diagonal braces and diagonal supports, which effectively mitigates mechanical impacts during driving. Fifth, the centralized layout of electrical accessories facilitates later inspection and maintenance, improving service convenience and module replacement efficiency. Sixth, this structure has good versatility and scalability, can be adapted to various electric heavy-duty truck platforms, and facilitates platform development and mass production.

[0010] Overall, this integrated structure takes into account space optimization, assembly efficiency, heat dissipation performance, and ease of operation and maintenance, providing an efficient, reasonable, and highly engineered solution for the arrangement of electric accessories in pure electric heavy trucks.

[0011] The second objective of this application is to provide a heavy-duty truck, wherein the heavy-duty truck is provided with a longitudinal beam, characterized in that: the longitudinal beam is equipped with the integrated structure of the heavy-duty truck's electrical accessories.

[0012] In the above technical solution, preferably, the integrated frame is fixed between the longitudinal beams by a frame connecting plate. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the integrated structure of electrical accessories for medium and heavy-duty trucks according to this utility model; Figure 2 This is a schematic diagram of the integrated rack structure in this utility model; Figure 3 This is a schematic diagram of the installation structure of the integrated rack in this utility model. Detailed Implementation

[0014] To make the objectives, technical solutions, and advantages of this utility model clearer, the following detailed description is provided in conjunction with embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this utility model.

[0015] To address the problems of low space utilization, complex assembly, inconvenient maintenance, and structural redundancy caused by the dispersed arrangement of electrical accessories in existing technologies, this utility model provides an integrated structure for electrical accessories in heavy-duty trucks, as well as the heavy-duty truck itself. To further illustrate the structure of this utility model, a detailed description is provided below in conjunction with the accompanying drawings: Please see Figure 1 and Figure 2 An integrated structure for electric accessories in a heavy-duty truck includes a steering motor 1, a thermal management module 2, an electric air compressor 3, a power electronics unit 4, and a high-voltage box 5. These components are existing essential parts for electric heavy-duty trucks. The steering motor provides electronic power assistance for precise steering control; the thermal management module regulates the temperature of the electric drive system and power battery to ensure they operate within a suitable temperature range; the electric air compressor replaces the traditional engine-driven compressor, providing the necessary compressed air for pneumatic systems such as braking; the power electronics unit converts and distributes electrical energy and controls motor operation; and the high-voltage box serves as the distribution center for high-voltage power, connecting the power battery to various high-voltage components to ensure the safe and efficient operation of the power system.

[0016] The integrated structure for heavy-duty truck electrical accessories includes an integrated frame 6, on which the steering motor, thermal management module, electric air compressor, power electronics unit, and high-voltage box are mounted. The integrated frame forms a three-layer mounting space from bottom to top. The electric air compressor is mounted in the lower layer, the steering motor in the middle layer, and the thermal management module, power electronics unit, and high-voltage box in the upper layer. This innovative three-layer spatial design arranges key electrical accessories of the heavy-duty truck in layers through the integrated frame, which not only improves the compactness and modularity of the overall layout but also significantly optimizes the heat dissipation path and vibration isolation effect of each component, reducing system energy consumption and maintenance difficulty. Placing the electric air compressor in the lower layer helps to lower the center of gravity and improve vehicle stability; the steering motor in the middle layer facilitates connection with the front axle system, reducing energy transfer paths and spatial interference; and the thermal management module, power electronics unit, and high-voltage box concentrated in the upper layer facilitates wiring, heat dissipation, and protection management, thereby achieving a more rational structure, higher performance, and more orderly system integration effect.

[0017] Specifically, the integrated frame includes a lower frame 6-1, a middle frame 6-2, and an upper frame 6-3. The lower frame is constructed as a rectangular frame forming a lower-level installation space, the middle frame is constructed as a horizontal frame forming a middle-level installation space at its upper part, and the upper frame is constructed as a horizontal frame forming an upper-level installation space at its upper part. Further, the middle frame is fixed to the front-middle part of the lower frame, and the upper frame is fixed to the upper part of the lower frame. A diagonal brace 6-4 is provided between the front parts of the middle frame and the lower frame, and a diagonal support is provided between the upper frame and the lower frame. The middle frame being fixed to the front-middle part of the lower frame effectively avoids lower-level space, improving space utilization; the upper frame being fixed to the upper part of the lower frame makes the overall structural height controllable and the center of gravity distribution reasonable, contributing to the dynamic stability of the vehicle. Furthermore, by incorporating diagonal bracing and inclined supports, the structural strength and vibration resistance between each layer are enhanced, preventing deformation or loosening caused by loads or road impacts during operation, and significantly improving the structural reliability and durability of the entire electric accessory system. This three-layer frame distribution combined with diagonal mechanical support layout has adaptability and expansion potential in electric heavy trucks with compact space, concentrated loads, and high requirements for electric accessory arrangement.

[0018] Furthermore, the lower frame, middle frame, and upper frame are all made of high-strength aluminum alloy, combining lightweight design with good rigidity. The surface is anodized to enhance corrosion resistance, making them suitable for long-term use under complex operating conditions in heavy trucks. The frames are welded together. The electrical accessories are installed in the following order: electric air compressor, steering motor, thermal management module, power electronics unit, and high-voltage box; simultaneously, high-voltage wiring harnesses, low-voltage wiring harnesses, and cooling pipes can also be installed and fixed along the integrated frame.

[0019] Example 2 A heavy-duty truck is provided with longitudinal beams 7, on which the integrated structure for heavy-duty truck electrical accessories described in Embodiment 1 is mounted. The integrated frame is fixed between the longitudinal beams by frame connecting plates. Please refer to [link to previous text]. Figure 3 .

[0020] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. An integrated structure for electrical accessories of a heavy-duty truck, comprising a steering motor, a thermal management module, an electric air compressor, a power electronics unit, and a high-voltage box, characterized in that: The device includes an integrated frame, on which the steering motor, thermal management module, electric air compressor, power electronics unit, and high-voltage box are mounted. The integrated frame is constructed to form a three-layer mounting space from bottom to top. The electric air compressor is mounted in the lower mounting space, the steering motor is located in the middle mounting space, and the thermal management module, power electronics unit, and high-voltage box are located in the upper mounting space.

2. The integrated structure for heavy-duty truck electrical accessories according to claim 1, characterized in that: The integrated frame includes a lower frame, a middle frame, and an upper frame; the lower frame is constructed as a rectangular frame that forms a lower installation space inside, the middle frame is constructed as a horizontal frame that forms a middle installation space on top, and the upper frame is constructed as a horizontal frame that forms an upper installation space on top.

3. The integrated structure for heavy-duty truck electrical accessories according to claim 2, characterized in that: The intermediate frame is fixed to the front middle part of the lower frame, and the upper frame is fixed to the upper part of the lower frame.

4. The heavy-duty truck electrical accessory integrated structure according to claim 3, characterized in that: A diagonal brace is provided between the front of the intermediate frame and the lower frame, and a diagonal support is provided between the upper frame and the lower frame.

5. A heavy-duty truck, wherein the heavy-duty truck is provided with longitudinal beams, characterized in that: The longitudinal beam is fitted with the heavy-duty truck electrical accessory integrated structure as described in any one of claims 1-4.

6. The heavy-duty truck according to claim 5, characterized in that: The integrated frame is fixed between the longitudinal beams by frame connecting plates.

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