Carrier for a carrier arrangement, procedure, carrier arrangement and motor vehicle

Abstract

Carrier (5) for a carrier arrangement (1) for receiving a drive energy storage device (3) of an electrically powered motor vehicle, wherein - the support (5) extends in a longitudinal direction, wherein - the support (5) has at least one channel (23) extending at least partially along the longitudinal direction of the support and integrated into the support (5), in which at least one conduit (17) is arranged, characterized in that a reinforcing element (43) is arranged in the support (5).

Description

[0001] The invention relates to a carrier for a carrier arrangement for receiving a drive energy storage device of an electrically powered motor vehicle, in particular a commercial vehicle, in particular a bus, a method for manufacturing such a carrier, a carrier arrangement for receiving a drive energy storage device of an electrically powered motor vehicle, in particular a commercial vehicle, in particular a bus and a motor vehicle, in particular a commercial vehicle, in particular a bus with such a carrier arrangement.

[0002] In a motor vehicle, particularly a bus, it is known to arrange an electric drive energy storage system on the roof of the bus by means of a roof-mounted structure. Such a roof-mounted structure is known from DE 10 2017 115 605 A1. The roof-mounted structure described there has a large number of stiffening elements and is therefore complex and difficult to install. A bus with an electric drive has several electrical cables that connect the drive energy storage system to the electric drive. Furthermore, the bus has several air conditioning fluid lines by means of which the drive energy storage system can be supplied with an air conditioning fluid. The relatively rigid and heavy lines are usually arranged within hollow beams of the bus. Additional insulation elements are necessary to increase energy efficiency.Installing the cables within the roof structure and assembling the entire roof structure is a complex process that can lead to damage to the cables themselves and personal injury during installation. Furthermore, the cables can chafe during bus operation. Due to the relatively large drive energy storage system in buses—as well as other commercial vehicles—which can weigh up to 500 kg per battery unit, a large number of electrical and air conditioning lines are required, demanding a considerable amount of interior space. The relatively high mass of the drive energy storage system necessitates sufficient mechanical stability in the roof structure, which also results in an undesirable increase in the overall mass of the structure.

[0003] From DE 10 2017 119 465 A1, a carrier device for receiving battery cells of a battery device of a vehicle is known, which has a first and a second side carrier, wherein the side carriers each have at least one side surface and each have at least one bottom surface for planar contact of a battery cell and are designed as an extruded profile.

[0004] German patent DE 10 2019 217 766 A1 states that a high-voltage battery of an electrically powered vehicle includes at least one battery module in whose housing a plurality of cylindrical battery cells are arranged, stacked coaxially in series with their end faces facing each other. At least one partition wall is arranged between the facing end faces of the battery cells within the module housing. This partition wall is part of a battery cooling system and is permeated by coolant.

[0005] German patent application DE 10 2016 213 832 A1 discloses a lower shell for a battery housing of a traction battery, comprising a tray with a base and side walls surrounding this base, and several partitions that divide the tray into individual compartments. Both the base and the partitions are formed from extruded profiles, with at least some of the extruded profiles used in the base being designed as hollow profiles and allowing a cooling fluid to flow through them.

[0006] Finally, DE 10 2020 212 709 A1 discloses a battery device comprising a housing that defines an interior space in which one or more battery modules of the battery device are arranged, wherein the housing includes a housing base body which preferably comprises or is formed by one or more extruded parts.

[0007] The invention is therefore based on the objective of providing a carrier for a carrier arrangement for receiving a drive energy storage device of an electrically powered motor vehicle, in particular a commercial vehicle, in particular a bus, a method for manufacturing such a carrier and a carrier arrangement for receiving a drive energy storage device of an electrically powered motor vehicle, in particular a commercial vehicle, in particular a bus, wherein the aforementioned disadvantages are reduced, preferably do not occur.

[0008] The problem is solved by providing the present technical teaching, in particular the teaching of the independent claims as well as the preferred embodiments disclosed in the dependent claims and the description.

[0009] The problem is solved in particular by creating a support for a support arrangement for receiving a drive energy storage device of an electrically powered motor vehicle, in particular a commercial vehicle, especially a bus. The support extends in a longitudinal direction. The support has at least one channel extending at least partially along the longitudinal direction and integrated into the support, in particular into the material of the support, in which at least one line, in particular an electrical line, in particular a high-voltage line of the drive energy storage device, or an air conditioning medium line of the drive energy storage device, is arranged.

[0010] The support structure has an advantageously integral design, making it relatively easy to assemble. Since the cables are integrated into the support structure, particularly into its material, additional insulation elements for the cables are advantageously unnecessary. This results in reduced energy losses, leading to a greater operating range. The elimination of additional insulation elements simplifies cable installation, reducing, and preferably preventing, damage to the cables and personal injury during installation. The support structure's mass is also advantageously reduced. During installation, the need to thread electrical and air conditioning lines into the support structure is eliminated. Furthermore, chafing of the cables is reduced, and preferably prevented.Integrating the lines into the support structure advantageously reduces the amount of installation space required inside the vehicle, especially a bus. The integrated lines also improve the bending resistance of the support structure, thus eliminating the need for numerous stiffening elements. Furthermore, the wall thickness of the support structure can be advantageously reduced.

[0011] In the context of this technical teaching, a beam is understood to be, in particular, a load-bearing component, especially a beam component. Such a beam component has a longitudinal beam extent and a profile oriented transversely to the longitudinal beam extent – ​​in a transverse extent – ​​also referred to as a beam profile. The transverse extent is, in particular, smaller than the longitudinal beam extent. Specifically, such a beam can be a T-beam, I-beam (also referred to as a double-T beam), U-beam, Z-beam, or L-beam.

[0012] According to the invention, a reinforcing element is arranged in the support, particularly in the support material. The reinforcing element advantageously increases the mechanical stability of the support. Advantageously, the reinforcing element can be provided only at those points subjected to higher mechanical loads. In particular, this allows for the creation of a customized support, a so-called tailored profile. Specifically, a surface of the reinforcing element is surface-treated, particularly chemically, mechanically, and / or by means of an energy beam. Advantageously, the surface treatment creates a highly resilient bond between the support material and the reinforcing element.

[0013] In one embodiment, the carrier has at least two channels. In particular, the electrical conductor, especially a high-voltage conductor, is arranged in a first channel of the two channels, and the air conditioning medium conductor is arranged in a second channel of the two channels.

[0014] In one embodiment, the carrier has a plurality of first channels, each containing an electrical conductor, in particular a high-voltage conductor. In particular, the carrier has a plurality of second channels, each containing an air conditioning fluid line.

[0015] According to a further development of the invention, the cable has a cable connection designed to be connected to the drive energy storage device. In particular, the cable connection has a screw connection and / or a plug connection and / or a locking connection by means of which the cable can be connected to the drive energy storage device.

[0016] According to a further development of the invention, the support has a double-T profile, and in particular, the support is designed as a double-T beam. The at least one channel is arranged in an intersection region of the double-T profile. In particular, the at least one channel is arranged in an intersection region of a web of the support and a flange of the support. In particular, the at least one channel is arranged adjacent to an intersection of the web and the flange.

[0017] Alternatively or additionally, the support is provided with a recess on one end face, particularly one oriented in a transverse direction. Advantageously, cables can be routed through this recess. This also reduces the mass of the support. Alternatively or additionally, the support is provided with a hollow chamber structure, particularly a honeycomb structure, with the walls of the hollow chamber structure extending along the longitudinal direction of the support. The hollow chamber structure is advantageously designed as an insulating element for the cables, thus eliminating the need for an additional insulating element. This results in lower energy losses and, consequently, a greater range.Alternatively or additionally, it is possible that the hollow chamber structure, in particular the walls, is designed in certain areas as a further conduit, which is set up to convey an additional medium, in particular another air conditioning medium.

[0018] The problem is also solved by providing a method for manufacturing a carrier according to the invention or a carrier according to one or more of the embodiments described above. In this method, the carrier is manufactured in a primary forming process. The carrier's at least one conductor is integrated into the carrier during this primary forming process by creating a channel in which the conductor is arranged. The advantages of this method are particularly evident in the aspects already explained in connection with the carrier.

[0019] In one embodiment, the reinforcing element of the carrier is integrated into the carrier during the primary forming process by forming a cavity in which the reinforcing element is or is arranged.

[0020] According to a further development of the invention, it is provided that an injection molding process and / or an additive manufacturing process, in particular a selective energy beam melting process, especially a laser melting process, also known as selective laser sintering (abbreviated: SLS), is used as the primary forming process. Alternatively or additionally, it is provided that a material selected from the group consisting of: a metallic material, a steel material, a steel alloy, an aluminum material, an aluminum alloy, a plastic, and a combination of at least two of the aforementioned materials, is used as the material for the primary forming process.

[0021] The advantages already mentioned are particularly pronounced when a plastic is used as the material for the primary forming process. Specifically, the conductors integrated into the carrier act like the fiber material of a fiber-reinforced composite, with the plastic carrier acting as a matrix for the composite. This leads to an increase in the bending section modulus while simultaneously reducing the carrier's mass.

[0022] The problem is also solved by creating a support arrangement for accommodating a drive energy storage device of an electrically powered motor vehicle, in particular a commercial vehicle. The support arrangement comprises at least one support according to the invention or a support according to one or more of the previously described embodiments as an intermediate support. The support arrangement further comprises an end support. The end support extends, in particular, in a longitudinal direction. The at least one intermediate support and the end support are arranged parallel to and spaced apart from one another, in particular transversely to the longitudinal direction of the end support and transversely to a longitudinal direction of the intermediate support.Between the end support and an intermediate support of the at least one intermediate support, and / or between a first intermediate support and a second intermediate support of the at least one intermediate support, a drive energy storage compartment is arranged, in particular formed, in particular delimited, and in particular enclosed. The advantages of the support arrangement are particularly evident in connection with the support itself, as already explained in connection with the support. Furthermore, the support arrangement is advantageously constructed without a large number of stiffening elements and can therefore be assembled relatively easily.

[0023] In one embodiment, the carrier arrangement has at least two drive energy storage compartments.

[0024] According to a further development of the invention, the end support has an end support profile that is open at least on one side, in particular a U-shaped support profile, wherein an opening of the end support profile is partially directed towards the drive energy storage space, in particular limiting or enclosing the drive energy storage space. In particular, a drive energy storage device can be arranged partially, in particular with its end regions, in the opening of the end support profile. In this way, a larger drive energy storage device can advantageously be arranged in the drive energy storage space, especially with identical external dimensions of the support arrangement.

[0025] According to a further development of the invention, the support arrangement also includes a drive energy storage device arranged in the drive energy storage compartment. The drive energy storage device is connected to the at least one conductor of the at least one intermediate support.

[0026] In one embodiment, the carrier arrangement has at least two drive energy storage devices.

[0027] The drive energy storage system is specifically designed to supply the electric drive of the motor vehicle with electrical energy. The drive energy storage system is, in particular, a high-voltage electrical battery storage system.

[0028] In one embodiment, the drive energy storage device is connected to the line, in particular to the electrical line, especially to the high-voltage line, and / or to the air conditioning medium line, by means of the line connection of the line.

[0029] In one embodiment, the at least one intermediate support has at least two channels. In particular, the electrical line is arranged in a first channel of the two channels. In particular, the air conditioning fluid line is arranged in a second channel of the two channels.

[0030] In one embodiment, the intermediate support has a plurality of first channels, each containing an electrical conductor. In particular, the intermediate support has a plurality of second channels, each containing an air conditioning fluid line.

[0031] According to a further development of the invention, the support arrangement additionally comprises at least one base plate which is connected to the at least one end support and / or the at least one intermediate support. Advantageously, this further increases the mechanical stability of the support arrangement.

[0032] In one embodiment, the support arrangement has two base plates: a first base plate and a second base plate. Specifically, when the support arrangement is installed in the motor vehicle as intended, the base plate is located below the at least one support. Specifically, when the support arrangement is installed in the motor vehicle as intended, the cover plate is located above the at least one support.

[0033] According to a further development of the invention, at least one support, selected from the at least one intermediate support and the end support, has at least one fastening point which is optionally configured to attach the drive energy storage device, the at least one base plate, or another element, in particular a bracket, in particular a cable holder, in particular a pluggable cable tie, to the at least one support. In particular, a fastening element can be attached to the at least one fastening point. Advantageously, the functional integration of the fastening elements reduces setup and assembly times.

[0034] In one embodiment, the fastening point has a bore, a thread or a flange, or is designed as a bore, a thread or a flange.

[0035] The problem is also solved by creating a motor vehicle, in particular a commercial vehicle, especially a bus, with at least one support arrangement according to the invention or a support arrangement according to one or more of the embodiments described above. The support arrangement is located in a roof area of ​​the motor vehicle, in particular above a passenger compartment of the motor vehicle. In connection with the motor vehicle, the advantages that have already been explained in connection with the support and the support arrangement arise in particular.

[0036] Alternatively, the support structure is arranged in a floor area of ​​the vehicle, particularly below the passenger compartment. Specifically, the support structure forms an underside, particularly a floor, of the passenger compartment. The support structure is particularly easy to install. Roof edge trim in the roof area is unnecessary. The aerodynamics of the vehicle, particularly the bus, can be improved due to a reduced vehicle height. Furthermore, the bending resistance of the underside of the passenger compartment, particularly the floor on which passengers move, can be increased. In particular, the hollow chamber structure provides excellent insulation against cold air entering the passenger compartment through the floor area.

[0037] According to a further development of the invention, the motor vehicle has at least one drive energy storage device arranged in the drive energy storage compartment of the support structure. The drive energy storage device is configured to supply the electric drive of the motor vehicle with electrical energy.

[0038] In particular, placing the drive energy storage system in the vehicle's floor area results in a lower center of gravity, thus improving driving dynamics. It also reduces, and preferably eliminates, the vehicle's tendency to roll over.

[0039] The invention will be explained in more detail below with reference to the drawing. The drawing shows: Fig. 1 a schematic representation of a first embodiment of a support arrangement, Fig. 2 a schematic representation of a first embodiment of a support, and Fig. 3 a schematic representation of a second embodiment of a support.

[0040] Fig. Figure 1 shows a schematic representation of a first embodiment of a support arrangement 1 for receiving a drive energy storage device 3 of an electrically powered motor vehicle in a side view.

[0041] The support arrangement 1 comprises at least one – here two – support 5 as an intermediate support 7. The support arrangement 1 further comprises one – here two – end support 9. The end support 9 extends, in particular, in a longitudinal direction extending into the plane of the image. The at least one intermediate support 7 and the end support 9 are arranged parallel to each other, in particular transversely to the longitudinal direction of the end support and transversely to a longitudinal direction of the intermediate support 7 that also extends into the plane of the image – represented by arrow A. This arrangement is spaced between the end support 9 and an intermediate support 7 of the at least one intermediate support 7 – represented by the dashed circle B – and / or between a first intermediate support 7.1 and a second intermediate support 7.1.2 - represented by the dashed circle C - of the at least one intermediate support 7, a drive energy storage space 11 is arranged, in particular formed, in particular limited, in particular enclosed.

[0042] In this embodiment, it is provided that the end carrier 9 has an end carrier profile that is open at least on one side, in particular a U-shaped carrier profile, wherein an opening 13 of the end carrier profile is partially directed towards the drive energy storage space 11, in particular limiting, in particular enclosing, the drive energy storage space 11.

[0043] In this embodiment, the support arrangement 1 further comprises the drive energy storage device 3, which is arranged in the drive energy storage compartment 11. The drive energy storage device 3 is connected to at least one line 17 – of which, for clarity, only some are designated with a reference numeral – in particular an electrical line 16 and / or an air conditioning medium line 21, of the at least one intermediate support 7. In particular, the drive energy storage device 3 is arranged in the opening 13 of the end support profile in certain areas, especially with its end area 18.

[0044] In this embodiment, the carrier arrangement 1 has three drive energy storage devices 3, namely a first drive energy storage device 3.1, a second drive energy storage device 3.2 and a third drive energy storage device 3.3.

[0045] In this embodiment, the drive energy storage device 3 is connected by means of a line connection 19 of the at least one line 17 to the at least one line 17, in particular to the electrical line 16, in particular to the high-voltage line, and / or to the air conditioning medium line 21.

[0046] In this embodiment, the intermediate support 7 has a plurality of first channels 23.1, in each of which an electrical line 16 is arranged. In particular, the intermediate support 7 has a plurality of second channels 23.2, in each of which an air conditioning medium line 21 is arranged.

[0047] In this embodiment, the support arrangement 1 further comprises a base plate 25 which is connected to the at least one end support 9 and / or the at least one intermediate support 7.

[0048] In this embodiment, the support arrangement 1 has the base plate 25 as a base plate. In particular, the base plate is arranged below the at least one support 5 when the support arrangement 1 is installed in the motor vehicle as intended.

[0049] In this embodiment, at least one support 5, selected from at least one intermediate support 7 and the end support 9, has at least one fastening point 27 – of which only a few are designated with a reference numeral by way of example – which is optionally configured to fasten the drive energy storage device 3, the at least one base plate 25, or another element, in particular a bracket, in particular a cable bracket, in particular a pluggable cable tie, to the at least one support 5. In particular, a fastening element 29, for example a screw, can be attached to the at least one fastening point 27.

[0050] In this embodiment, the fastening point 27 has a bore, a thread or a flange, or is designed as a bore, a thread or a flange.

[0051] Fig. Figure 2 shows a schematic representation of a first embodiment of the support 5 of the support arrangement 1 according to Fig. 1 in an isometric view.

[0052] In this context, identical and functionally equivalent elements in all figures are provided with the same reference symbols, so that reference is made to the preceding description in each case.

[0053] The support 5 shown here corresponds to at least one intermediate support 7 in Fig. 1.

[0054] The support 5 extends in the longitudinal direction shown by arrow D. The support 5 has at least one channel 23 extending at least partially along the longitudinal direction and integrated into the support 5, in particular into the material of the support 5, in which the at least one line 17, in particular the electrical line 16, in particular a high-voltage line of the drive energy storage device 3, or the air conditioning medium line 21 of the drive energy storage device 3, is arranged.

[0055] In this embodiment, the line 16 is provided to have the line connection 19 (not shown here), which is designed to be connected to the drive energy storage unit 3.

[0056] In this embodiment, it is provided that the support 5 has a recess 41 on an end face 39, in particular oriented in a transverse direction of the support.

[0057] In this configuration, the carrier 5 has eight channels 23. Six electrical lines 16 and two air conditioning medium lines 21 are arranged in the eight channels 23.

[0058] Fig. Figure 3 shows a schematic representation of a second embodiment of the support 5 of the support arrangement 1 according to Fig. 1 in a front view.

[0059] In particular, the support 5 of the second embodiment is a further development of the support 5 of the first embodiment according to Fig. 2.

[0060] In this embodiment, the support 5 is provided to have a double-T profile, and in particular, the support 5 is designed as a double-T beam. The at least one channel 23 is arranged in a crossing area 31 of the double-T profile.

[0061] In particular, at least one channel 23 is arranged in an intersection area 31 of a web 33 of the girder 5 and a flange 35 of the girder 5. In particular, at least one channel 23 is arranged adjacent to an intersection 37 of the web 33 and the flange 35.

[0062] In this embodiment, it is provided that a reinforcing element 43 is arranged in the support 5, in particular in the material of the support 5.

[0063] In this embodiment, the support 5 is provided to have a hollow chamber structure 45, in particular a honeycomb structure, wherein walls 47 of the hollow chamber structure 45 extend along the longitudinal direction of the support extending into the image plane.

Claims

[1] Carrier (5) for a carrier arrangement (1) for receiving a drive energy storage device (3) of an electrically powered motor vehicle, wherein - the support (5) extends in a longitudinal direction, wherein - the support (5) has at least one channel (23) extending at least partially along the longitudinal direction of the support and integrated into the support (5), in which at least one conduit (17) is arranged, characterized by , that a reinforcing element (43) is arranged in the support (5). [2] Carrier (5) according to claim 1, wherein - the line (17) has a line connection (19) which is set up to be connected to the drive energy storage device (3). [3] Carrier (5) according to any one of the preceding claims, wherein - the support (5) has a double-T profile, wherein - which at least one channel (23) is arranged in a crossing area (31) of the double-T profile. [4] Carrier (5) according to any one of the preceding claims, wherein - the carrier (5) has a recess (41) on one end face (39), and / or wherein - the support (5) has a hollow chamber structure (45), wherein walls (47) of the hollow chamber structure (45) extend along the longitudinal direction of the support. [5] Method for producing a carrier (5) according to any one of the preceding claims, wherein - the carrier (5) is produced in a primary forming process, whereby - the at least one conduit (17) of the carrier (5) is integrated into the carrier (5) in the primary forming process by forming a channel (23) in which the conduit (17) is or is arranged during the primary forming process. [6] Method according to claim 5, wherein - an injection molding process and / or an additive manufacturing process is used as the primary forming process, and / or - the material used for the primary forming process is a material selected from a group consisting of: a metallic material, a steel material, a steel alloy, an aluminum material, an aluminum alloy and a plastic. [7] Carrier arrangement (1) for receiving a drive energy storage device (3) of an electrically powered motor vehicle, comprising: - at least one support (5) according to one of claims 1 to 4 as an intermediate support (7), and - an end carrier (9) - the at least one intermediate support (7) and the end support (9) are arranged parallel and spaced apart from each other, wherein - a drive energy storage space (11) is arranged between the end carrier (9) and an intermediate carrier (7) of the at least one intermediate carrier (7) and / or between a first intermediate carrier (7.1) and a second intermediate carrier (7.2) of the at least one intermediate carrier (7). [8] Carrier arrangement (1) according to claim 7, wherein the end carrier (9) has an end carrier profile that is open at least on one side, wherein an opening (13) of the end carrier profile is partially directed towards the drive energy storage space (11). [9] Carrier arrangement (1) according to one of claims 7 or 8, further comprising: - a drive energy storage device (3) which is arranged in the drive energy storage storage space (11), wherein - the drive energy storage device (3) is connected to the at least one line (17) of the at least one intermediate support (7). [10] Carrier arrangement (1) according to one of claims 7 to 9, further comprising: - at least one base plate (25) connected to the at least one end support (9) and / or the at least one intermediate support (7). [11] Carrier arrangement (1) according to any one of claims 7 to 10, wherein - at least one support (5), selected from the at least one intermediate support (7) and the end support (9), has at least one attachment point (27) which is optionally configured to attach the drive energy storage device (3), the at least one base plate (25), or another element to the at least one support (5), wherein - the fastening point (27) preferably has a bore, a thread or a flange, or is designed as a bore, a thread or a flange. [12] Commercial vehicle, with at least one support arrangement (1) according to one of claims 7 to 11, wherein the support arrangement (1) is arranged in a roof area of ​​the commercial vehicle or in a floor area of ​​the commercial vehicle. [13] Commercial vehicle according to claim 12, wherein the commercial vehicle has at least one drive energy storage device (3) which is arranged in the drive energy storage storage space (11) of the carrier arrangement (1), wherein the drive energy storage device (3) is configured to supply an electric drive of the commercial vehicle with electrical energy.

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