Commercial vehicle with modular battery box

Abstract

The invention relates to a commercial vehicle, in particular a battery-electrically powered trailer (20) for coupling to a tractor, comprising a chassis (21) formed by longitudinal and transverse beams (23, 24), on the underside (22) of which at least one, in particular two or three trailer axles are arranged, wherein at least one axle is equipped with an electric drive unit for driving and decelerating the commercial vehicle, and at least one battery box (10) which is arranged on the underside (22) of the chassis (21) and serves to accommodate replaceable battery modules (50).According to the invention, a suspension device (30) is provided which detachably connects the battery box (10) to the chassis (21), wherein the battery box (10) is mounted on the chassis (21) via the suspension device (30) in such a way that it is mechanically decoupled from the chassis (21), wherein the battery box (10) is of modular design and has a modular cage structure (15) which is formed by at least one upper frame (11) for detachably fixing to the suspension device (30) and at least one parallel lower frame (12) for receiving replaceable battery modules (50) and for detachably fixing to the upper frame (11), in order to enable a quick and safe exchange of battery modules (50) from bottom to top or from top to bottom.

Description

[0001] The invention relates to a commercial vehicle, in particular a battery-electrically powered trailer for coupling to a tractor, according to the preamble of claim 1 and to a method for the safe and rapid replacement of battery modules according to claim 20.

[0002] Trailers (also known as semi-trailers, semi-trailers, or semi-trailers) are generally used for transport and work purposes, for example, in road freight transport or agriculture. For a long time, they were considered non-motorized commercial vehicles and are usually mounted and towed via a so-called kingpin on the fifth wheel of a usually diesel-powered tractor unit.

[0003] Trailers typically have a chassis or ladder frame constructed from cross and longitudinal beams and are usually multi-axle. Trailers and semi-trailers have two or three axles, respectively.

[0004] With the ongoing development of electromobility, alternative drive concepts have emerged that equip the trailer with an additional electric drive unit to support the tractor unit. For example, one of the one, two, or three trailer axles can be equipped with an electric motor / gearbox unit. This opens up the possibility of supporting the tractor unit during propulsion and deceleration phases via the trailer drive as needed, thereby improving the overall energy efficiency of the commercial vehicle. Due to the nature of the system, large and heavy high-voltage battery modules are required to supply energy to such a trailer. The HV battery modules must be securely mounted on the trailer chassis in a battery box.

[0005] In this context, particular space-related issues arise. Furthermore, the battery storage must meet increased safety requirements and dynamic loads due to the high-voltage components. Furthermore, the structural integrity of the battery box is subject to stringent requirements. The battery modules housed in the battery box must be effectively protected against environmental influences such as moisture and dust. Protecting the electrical components requires a relatively rigid structure. However, the trailer chassis has significantly greater flexibility in terms of requirements than the battery box. Torsionally flexible chassis, in particular, pose significant challenges for connecting the relatively rigid battery box.

[0006] To achieve the greatest possible range, especially for battery-electric commercial vehicles or trailers, it is fundamentally necessary to carry a correspondingly large battery capacity. Existing battery modules are therefore heavy and have the disadvantage of long charging times, which limits the vehicle's payload and reduces its operating time due to potentially long charging times. Furthermore, the high weight of the battery modules leads to losses in the payload of the vehicle or its combination.

[0007] For example, DE 10 2022 123 162 B3 already proposes commercial vehicles with partially modular battery box or cage structures, which, however, are limited by various structural and functional disadvantages. The proposed solutions also include a lack of modularity, flexibility, and, in particular, problems with the maintenance and replacement of battery modules. As a result, rapid battery module replacement, for example, at a designated exchange station, is often not possible, and very heavy battery modules must be carried, which directly provide the entire energy capacity required for the route.

[0008] Furthermore, WO 2023 / 116483 A1 describes a battery pack for an electric vehicle and an electric vehicle with such a battery pack. The battery pack for the electric vehicle comprises a plurality of battery receiving areas arranged in a width direction of the electric vehicle, wherein the plurality of battery receiving areas comprises a central receiving area and lateral receiving areas, and each battery receiving area can accommodate multiple layers of battery modules.

[0009] The object of the present invention is therefore to overcome the disadvantages of the prior art and to provide a commercial vehicle, in particular a battery-electric driven trailer, with an improved battery box.

[0010] Main features of the invention are defined in the characterizing part of claim 1. Embodiments are the subject of claims 2 to 20.

[0011] In a commercial vehicle, in particular a battery-electrically powered trailer for coupling to a tractor, comprising a chassis formed by longitudinal and transverse beams, on the underside of which at least one trailer axle is arranged, wherein the at least one trailer axle is equipped with an electric drive unit for driving and decelerating the commercial vehicle, and at least one battery box which is arranged on the underside of the chassis and serves to accommodate replaceable battery modules, a suspension device is provided according to the invention which detachably connects the battery box to the chassis, wherein the battery box is mounted on the chassis via the suspension device in such a way that it is mechanically decoupled from the chassis, wherein the battery box is of modular design and has a modular cage structure,which is formed by at least one upper frame for releasably fixing to the suspension device and at least one parallel lower frame for receiving replaceable battery modules and for releasably fixing to the upper frame in order to enable a quick and safe exchange of battery modules from bottom to top or from top to bottom.

[0012] Due to the modular battery box according to the invention, which is attached to the chassis via a completely mechanically decoupled suspension device and supports easy replacement of battery modules via its modular cage structure, a multitude of technical advantages are offered.

[0013] Mechanical decoupling effectively isolates vibrations and shocks that occur during driving from the battery box and the battery modules it contains. This not only increases the service life of the battery modules by minimizing mechanical stress, but also improves the driving safety and stability of the entire commercial vehicle.

[0014] Mechanical decoupling from the chassis refers to a design measure in which the battery box is mounted on the chassis of a commercial vehicle, in particular a battery-electric trailer, in such a way that there is no direct mechanical connection that could transmit loads, vibrations or shocks to the battery box structure. This can be achieved through the use of special mounting elements such as silent blocks, which act as elastic and damping connecting elements. These silent blocks isolate the battery box in such a way that driving dynamic loads caused by the movement of the vehicle (e.g. due to uneven road surface, cornering or braking), preferably in the longitudinal direction L, transverse direction Q and vertical direction H, are not transferred to the battery box. The mechanical decoupling positively isolates driving dynamic loads that arise during vehicle operation.Isolation means that chassis movements, such as twisting, oscillations, shocks, and vibrations that occur during driving, have a significantly reduced impact on the battery box. This measure also supports the battery module replacement process.

[0015] According to the invention, mechanical decoupling is achieved through a special bearing arrangement in which the battery box is connected to the chassis only via the silent blocks. These silent blocks are made of an elastic material that largely absorbs the forces generated and minimizes the transfer of kinetic energy to the battery box. This ensures that the battery box remains in a stable and quiet position even under strong dynamic loads, such as those that occur when driving on uneven roads or when braking. The sensitive battery modules are thus always protected from mechanical influences, which extends their service life and increases safety. In summary, mechanical decoupling ensures that dynamic driving loads are effectively isolated, thus protecting the battery box from mechanical stresses that act on the battery box from the chassis due to driving dynamics.

[0016] The modular cage structure of the battery box also allows for easy adaptation to different battery module sizes and ensures quick, safe replacement of the battery modules. This is particularly advantageous in applications where high vehicle availability is crucial, as downtime for charging or servicing the batteries is minimized. Replacing the battery modules from top to bottom means removing a discharged battery in a vertical direction from top to bottom and inserting a charged battery from bottom to top. The inventive modularity of the cage structure and the simple and quick replaceability of the battery modules accommodated therein advantageously offers a flexible and adaptable design in which the structure of the battery box is constructed to be suitable for different battery capacities and types.The modular structure consists of individual components and is preferably designed according to a modular system, allowing it to be easily assembled, replaced, or adapted. This allows the structure to be configured and adapted for differently sized battery modules without great effort. Overall, this design enables greater operational efficiency and reduces long-term maintenance and operating costs.

[0017] The invention thus enables the carrying of a smaller battery capacity and thus a lower battery weight. This significantly increases energy efficiency during driving. Furthermore, the battery-electric vehicle can be equipped as needed for the distance to be covered, in terms of the battery capacity carried. With an appropriate infrastructure, such as charging / swapping stations, further efficiency improvements can be achieved and the invention can be further supported.

[0018] Overall, the invention offers several advantages in terms of function, cost, quality, service life, deterioration, wear, manufacturing and safety.

[0019] According to the invention, the suspension device comprises fixing profiles that can be releasably fixed to the longitudinal members on both frame sides of the chassis. The fixing profiles have flat and vertically aligned contact surfaces for engaging an inner profile of the longitudinal members and two support arms each for resting on the surfaces of mounting rails. The fixing profiles, which are releasably fixed to the longitudinal members of the chassis, ensure an extremely stable yet flexible attachment of the battery box to the chassis. The vertical alignment of the contact surfaces ensures precise positioning and facilitates the installation of the battery box, as the fixing profiles enable a secure and repeatable connection. The support arms of the fixing profiles provide additional stabilization by evenly distributing the weight of the battery box across the mounting rails.This design ensures secure attachment while allowing easy removal when battery modules need to be replaced or serviced. This increases the flexibility and maintainability of the system, which in turn reduces vehicle downtime.

[0020] Preferably, the support arms of the fixing profiles of the suspension device can extend in the transverse direction, whereby the support arms of the fixing profiles can be L-shaped. The L-shaped support arms, which extend in the transverse direction, significantly improve the structural stability of the suspension device. The shape of the support arms optimally transfers the load of the battery box to the suspension, thereby minimizing deformation or movement during driving. This not only ensures increased safety of the battery box and the battery modules contained therein, but also improves the driving dynamics of the commercial vehicle. The even load distribution and robust fastening help ensure that the battery box remains securely in position even in the event of strong vibrations or impacts, which further increases the operational reliability and longevity of the system.

[0021] According to a preferred embodiment, the suspension device can comprise at least two mounting rails arranged parallel to the longitudinal members on both sides of the chassis frame, wherein the mounting rails can be designed to be applied to the fixing profiles of the suspension device. The mounting rails, which are arranged parallel to the longitudinal members of the chassis, provide a solid and flexible base for attaching the suspension device and thus the entire battery box. These rails enable easy adaptation of the suspension device to different vehicle models, which significantly expands the application possibilities of the modular battery box. The mounting rails also offer increased flexibility in the arrangement and orientation of the fixing profiles, which simplifies and accelerates the installation process.This modularity helps ensure that the battery box can be easily installed on different vehicle types and quickly removed when necessary, further improving operational efficiency and ease of maintenance.

[0022] Preferably, the suspension device can comprise at least two support rails on each of the two sides of the chassis frame, which are aligned parallel to the longitudinal members and can have fixing elements for releasably connecting the support rails to the upper frame of the modular cage structure. Two support rails arranged side by side in the longitudinal direction can have a longitudinal extension that approximately corresponds to the longitudinal extension of a mounting rail arranged in the longitudinal direction. The support rails, aligned parallel to the longitudinal members and equipped with fixing elements, offer reliable and flexible fastening of the upper frame of the modular cage structure to the chassis. This design enables precise adaptation of the battery box to different battery module sizes and capacities and ensures stable accommodation and fixing of the battery modules.The ability to flexibly position the mounting rails longitudinally contributes to the battery box being optimally adapted to specific requirements, increasing the versatility and flexibility of the system. Furthermore, this design facilitates the replacement and maintenance of the battery modules, as the battery box is securely and stably attached to the chassis, yet easily removable.

[0023] According to a further preferred embodiment, it is conceivable for the mounting rails and the support rails to have U-shaped profiles, wherein the support rails can each be arranged below the mounting rails and simultaneously next to each other in the longitudinal direction. The U-shaped profiles of the mounting rails and support rails offer the advantage of increased structural stability while reducing weight. This profile shape enables efficient distribution of mechanical loads and improves the system's resistance to dynamic loads. At the same time, the U-shape facilitates the precise alignment and assembly of the modular cage structure on the chassis, which simplifies the installation process and increases safety.The arrangement of the support rails under the mounting rails and their parallel longitudinal alignment also enables efficient use of space, which further improves the flexibility of the system and allows easy adaptation to different vehicle configurations.

[0024] According to the invention, the suspension device comprises elastic and vibration-damping silent mounts for adjusting the mechanical decoupling of the battery box. The silent mounts can preferably be arranged on both sides of the chassis frame and can be designed as silent blocks to isolate vibrations and shocks while facilitating the replacement of the battery modules. The use of elastic and vibration-damping silent mounts for the mechanical decoupling of the battery box from the chassis offers numerous advantages. These silent mounts effectively isolate the battery box from vibrations and shocks that act on the chassis during driving. This protects the sensitive battery modules from mechanical stress, extending their service life and increasing their functional reliability.In addition, the silent blocks facilitate battery module replacement by allowing movement along multiple axes, ensuring flexible handling of the battery box. This reduces maintenance time and increases the vehicle's efficiency in daily operation.

[0025] Preferably, the silent mounts can dampen and isolate dynamic driving loads in the longitudinal, transverse, and vertical directions of the trailer to achieve complete mechanical decoupling of the battery box. The silent mounts can be designed and arranged in such a way that they stabilize the battery box in its position while simultaneously allowing mechanical movement in multiple axes to completely isolate dynamic driving loads. The ability of the silent mounts to dampen and isolate dynamic driving loads in the longitudinal, transverse, and vertical directions significantly improves the stability and safety of the battery box while driving. This property ensures that the battery box remains securely and stably in position even under strong dynamic loads, such as those encountered during cornering, braking maneuvers, or driving over uneven roads.This not only reduces the risk of damage to the battery modules but also contributes to the overall driving stability of the commercial vehicle. Complete isolation from dynamic loads also further increases the service life of the battery box and the battery modules it contains, enhancing the system's long-term reliability and efficiency.

[0026] According to a further preferred embodiment, the silent bearings can be arranged in a form-fitting manner between the mounting rails and the receiving rails of the suspension device and can be releasably and force-locked to the mounting and receiving rails via fastening elements. The silent bearings can have base plates on their undersides that rest on the surfaces of the receiving rails. The form-fitting arrangement of the silent bearings between the mounting rails and receiving rails provides an extremely stable and secure connection that is also easily removable. This design enables simple and precise installation of the battery box on the chassis and ensures that the battery box remains securely in position even under extreme operating conditions.The base plates attached to the underside of the silentblocs provide a stable support surface, ensuring even load distribution and increasing the mechanical stability of the system. These features not only facilitate the assembly and disassembly of the battery box, but also contribute to reducing wear and maintenance costs, further improving the vehicle's operating efficiency and, positively, facilitating the battery module replacement process.

[0027] Preferably, the modular cage structure of the battery box can be provided with additional reinforcement elements to increase its load-bearing capacity under high dynamic loads. These additional reinforcement elements can be formed by transversely extending crossbeams, which can have recesses for stiffening and weight reduction. The additional reinforcement elements in the modular cage structure of the battery box offer a significant improvement in structural strength and load-bearing capacity, particularly under high dynamic loads. These reinforcement elements, formed by transversely extending crossbeams, ensure that the battery box remains stable even under extreme operating conditions and that the battery modules contained therein are reliably protected.The recesses in the cross members serve to reduce weight without compromising structural integrity, increasing the vehicle's efficiency by reducing overall weight. These features contribute to extending the lifespan of the battery box and improving vehicle safety.

[0028] According to a preferred embodiment, the upper and / or lower frame of the modular cage structure of the battery box can be formed by transversely aligned corner and cross members and longitudinally arranged lateral longitudinal members, wherein the lateral longitudinal members also function as side impact protection and the modular cage structure of the battery box can be adapted to accommodate battery modules of different sizes and capacities. The use of corner and cross members as well as lateral longitudinal members to form the frame of the modular cage structure offers an optimal combination of structural strength and flexibility. This design enables precise adaptation of the battery box to different battery module sizes and capacities and ensures stable and secure accommodation of the battery modules.The side longitudinal members also function as side impact protection, significantly increasing vehicle safety in the event of a side impact. This modular design allows the cage structure to be flexibly adapted to different operating requirements, increasing the system's versatility and reducing production costs, as the same basic structure can be used for different vehicle models.

[0029] Further preferably, the modular cage structure of the battery box can be designed to be adaptable in the vertical and longitudinal directions in order to configure the receiving structure for battery modules of different sizes. The modular cage structure can be designed to be mirror-symmetrical to a central longitudinal axis of the chassis, so that identical structures for receiving replaceable battery modules can be created on both frame sides of the chassis. The adaptability of the modular cage structure in the vertical and longitudinal directions enables a flexible configuration of the receiving structure for battery modules of different sizes, which significantly increases the versatility of the system. This flexibility ensures that the battery box can be adapted to different battery module sizes, arrangements, and capacities without extensive changes to the basic structure being required.The mirror-symmetrical design of the cage structure to a central longitudinal axis of the chassis makes it possible to create identical structures for accommodating battery modules on both sides of the chassis frame, which increases efficiency in the assembly and maintenance of the vehicle and reduces production costs through the standardization of components.

[0030] Preferably, the modular cage structure of the battery box can include an integrated device for temperature monitoring and cooling the battery modules to ensure the optimal operating temperature. The modular cage structure of the battery box can be equipped with standardized interfaces that can enable compatibility with different battery module types. The integrated temperature monitoring and cooling device in the modular cage structure ensures that the battery modules always operate under optimal temperature conditions, increasing their efficiency and service life. Continuous monitoring of the operating temperature ensures that the batteries are protected from overheating, reducing the risk of failure or damage.Furthermore, the use of standardized interfaces enables easy integration of different battery module types, increasing the flexibility of the system and ensuring compatibility with future battery technologies. This contributes to the future-proofing of the vehicle and increases its adaptability to changing technical requirements.

[0031] According to a preferred embodiment, the modular cage structure of the battery box can comprise a plurality of replaceable battery modules arranged vertically stacked, which are accommodated in the modular cage structure and can be securely held. The modular cage structure can be designed to ensure accessibility or an operating space for robot arms or corresponding tools used for changing the battery modules. The possibility of arranging a plurality of battery modules stacked vertically maximizes the energy density of the vehicle, which leads to increased range and efficiency. This stacking allows for optimal use of the available space in the battery box, which is particularly advantageous in applications with limited installation space.The modular cage structure is designed to provide easy access for robotic arms or tools used to replace the battery modules. This facilitates the automated replacement process and minimizes human error, resulting in increased vehicle uptime and lower maintenance costs.

[0032] Further preferably, the modular cage structure and the battery modules can have separable connections for high-voltage lines, coolant lines, and control lines, which can enable the quick separation and connection of the replaceable battery modules. The upper and lower frames of the modular cage structure can have separable interfaces with fastening elements for detachable connection and complementary receiving elements, which can be formed by screw connections or quick-couplings or locking elements or connection pins or plug connections, in order to offer the possibility of positioning and aligning the battery box accordingly for a quick and safe replacement process. The use of separable connections for high-voltage lines, coolant lines, and control lines enables the battery modules to be separated and connected quickly and safely, which significantly accelerates the replacement process.These detachable interfaces ensure that the electrical and mechanical connections can be easily and reliably disconnected and reconnected when replacing battery modules, reducing the risk of damage and increasing safety. The ability to precisely position and align the battery box ensures that the replacement process can be carried out efficiently and without complications, further improving the vehicle's operating efficiency.

[0033] According to a further preferred embodiment, the modular cage structure of the battery box can be equipped with additional guide elements and guide rails that can ensure precise alignment and positioning of the battery modules during the insertion and removal process from bottom to top or from top to bottom in the vertical direction. The guide elements for the battery modules can be designed in such a way that they can enable automatic self-correction of the battery modules during the replacement process, even in the event of minimal deviations in positioning. The additional guide elements and guide rails in the modular cage structure ensure precise alignment and positioning of the battery modules during the insertion and removal process. This function minimizes the risk of incorrect positioning that could lead to damage to the battery modules or the battery box.Automatic self-correction of the positioning minimizes human error in the replacement process, increasing the reliability and safety of the system. This precise alignment also helps ensure that the replacement process can be completed quickly and efficiently, reducing vehicle downtime and lowering operating costs.

[0034] Preferably, the modular cage structure of the at least one battery box can be provided with an additional protection system that protects cyclists and pedestrians from being underrun, in particular by being designed in accordance with the requirements of Directive ECE-R73. The battery box can comprise a front and a rear attachment structure to improve aerodynamics and to additionally accommodate battery accessories. The additional protection system, which protects cyclists and pedestrians from being underrun, significantly increases the road safety of the vehicle. This safety device, which is designed in particular in accordance with the requirements of Directive ECE-R73, not only protects other road users but also contributes to the vehicle's compliance with applicable safety regulations.The front and rear attachment structures improve aerodynamics and reduce drag, thus lowering energy consumption and increasing the vehicle's range. At the same time, these structures provide space for battery accessories, further increasing the system's flexibility and improving overall system efficiency.

[0035] According to a further preferred embodiment, the modular cage structure of the battery box can have an additional protective cladding, in particular a sheet metal cladding, which protects the replaceable battery modules from environmental influences and simultaneously provides electromagnetic shielding. The protective cladding of the battery box can comprise a lightweight metal material to optimize weight while simultaneously providing sufficient shielding, and the protective cladding of the battery box can be sealed with a weather-resistant adhesive sealant at all interfaces and connection points of the modular cage structure. The additional protective cladding made of lightweight metal offers effective protection for the battery modules from harmful environmental influences such as moisture, dust, and mechanical damage. This increases the service life of the battery modules and contributes to the reliability of the system.At the same time, the protective cover provides electromagnetic shielding, preventing electromagnetic interference from affecting the battery modules or the vehicle's electronic control system. The use of a lightweight metal material optimizes the weight of the protective cover, which contributes to reducing the overall weight of the vehicle and increases energy efficiency. The weather-resistant sealing of the cover with an adhesive sealant at all interfaces and connection points ensures that the battery modules are permanently protected from moisture penetration, further increasing the longevity of the system.

[0036] Preferably, the battery module replacement process can be performed manually using tools or fully automatically using a dedicated robotic device for replacing the battery modules. The ability to perform the battery module replacement process either manually or fully automatically offers high flexibility in maintenance and adapts the system to different operational requirements. Manual replacement allows the process to be performed using simple tools, which is particularly advantageous in less well-equipped maintenance facilities. Fully automated replacement, on the other hand, significantly increases the efficiency and precision of the process by enabling the use of specialized robotic devices that accelerate the replacement process and minimize the risk of human error.This flexibility helps reduce maintenance costs and ensures that the replacement process can be carried out quickly and reliably, maximizing vehicle uptime.

[0037] According to a further preferred embodiment, the trailer chassis can have two spaced-apart battery boxes with accommodated replaceable battery modules, each of which is mounted on both sides of the chassis frame via suspension devices. The suspension devices of the two battery boxes on each side of the chassis frame can each provide at least three fixing profiles and at least four silent bearings for mounting the battery boxes on the longitudinal members of the chassis. The arrangement of two spaced-apart battery boxes on the trailer chassis enables even weight distribution, which improves the vehicle's driving stability and reduces the risk of tipping or instability.The use of suspension systems with multiple fixing profiles and silent bearings ensures secure and stable mounting of the battery boxes, further increasing the safety and reliability of the system. This design allows the battery boxes to be quickly removed and replaced when necessary, facilitating maintenance and increasing the vehicle's operating efficiency. Furthermore, the spatial separation of the battery boxes improves cooling performance and reduces the risk of overheating, thus extending the service life of the battery modules.

[0038] According to a preferred embodiment, the lower frame of the modular cage structure can be equipped with conical connecting pins, which enable precise positioning during insertion and locking. The opposite side, i.e., the upper frame of the modular cage structure, can preferably have correspondingly complementary receiving points or receiving elements, which can be designed in particular according to the principle of the Reference Point System (RPS). These receiving points positively ensure that the battery modules can be precisely positioned during the swap. Furthermore, the conical connecting pin or the conical quick connection offers the advantage that small misplacements of the vehicle within the swapping station can be compensated for by the tapered pins during the swapping process.These pins allow the battery carrier frame to automatically align itself to its so-called zero position during the insertion process. A corresponding kinematic clearance can preferably be provided in the design to enable this automatic correction. This contributes to making the process of changing battery modules and / or elements of the cage structure more efficient and error-resistant by compensating for minor positioning deviations in the vehicle, thus ensuring precise locking of the battery modules.

[0039] According to a further preferred embodiment of the invention, the battery modules can be locked in place by special locking elements, in particular by T-shaped locking elements, which can be released or locked either manually or by robots. The corresponding locking points are provided by the modular cage structure.

[0040] The frames of the modular cage structure of the modular battery box can preferably be constructed mirror-symmetrically, creating structural segment chambers into which the battery modules can be inserted and removed from below using suitable replacement tools. These modules are securely locked or released. The modular cage structure can preferably be provided with corresponding special recesses to insert the longitudinal member bottom chords into the space-related support structure, thus ensuring maximum ground clearance for the vehicle.

[0041] The distribution of two modular battery boxes, each containing four separately mounted battery modules, can preferably be designed in such a way that the battery weights along the vehicle's axles ensure balance, which can advantageously reduce the fifth wheel load when unladen. This balancing follows the principle of the classic lever law and contributes to reducing the load on the tractor's fifth wheel plate. This has a positive impact on the payload capacity of the vehicle or trailer, as the vehicle is better balanced overall and can carry a higher load without excessive strain on the axles.

[0042] Further preferably, the modular cage structure can be designed adaptively in such a way that it can adapt to the different requirements and installation positions in different vehicle categories, in particular in vehicle category O.

[0043] Preferably, the modular cage structure of the battery box can be designed to securely hold the battery modules while allowing for quick and efficient replacement if necessary. When fully equipped with four battery modules, this preferably results in a usable battery capacity of approximately 712 kWh, with a nominal capacity of 890 kWh.

[0044] Protection against moisture and dirt can also preferably be implemented at the component level to save costs in development and production. Such a solution would reduce the need for expensive, comprehensive protective devices while ensuring the reliability of individual components.

[0045] According to a fundamentally alternative design variant, the decoupling between the battery box structure and the chassis of the trailer or commercial vehicle can be omitted. In this case, the battery box structure could be welded, riveted, or bolted directly to the chassis. This method would create a more direct and potentially more robust connection. The battery box would not have to be aerodynamically optimized, and the protection of cyclists and pedestrians could be implemented as a supplementary add-on solution beyond the limits of the battery box structure. According to this embodiment, it can further be preferably provided that the chassis of the trailer is designed to be correspondingly torsionally rigid.

[0046] According to an alternative preferred embodiment, the modular cage structure can be designed to allow lateral removal of the battery modules. This could be particularly useful when the vehicle's ground clearance is reduced or when swapping stations do not offer the possibility of lowering the battery below ground level (for example, in a pit). This alternative removal method could offer significant spatial advantages in certain scenarios, even if it may not always appear to be the most efficient solution at first glance. A swapping station is a specially equipped facility used to quickly and efficiently exchange the battery modules of electrically powered vehicles, in particular commercial vehicles such as battery-electric trailers.In a swapping station, discharged battery modules are removed automatically or manually and replaced with fully charged modules without the vehicle being idle for extended periods. This enables a quick resumption of driving and reduces downtime compared to conventional battery charging.

[0047] According to a further aspect, the invention relates to a method for the quick and safe replacement of HV battery modules in a commercial vehicle, in particular in a battery-electrically powered trailer, with a modular battery box, comprising the steps of: positioning the commercial vehicle over a replacement device; decoupling separable connections for high-voltage lines, coolant lines and control lines while the battery modules are safely released and lowered from top to bottom through the guide rails and guide elements; removing the discharged battery modules from the battery box; inserting the new, charged battery modules from bottom to top through the guide rails and guide elements into the modular battery box; automatic self-correction and locking of the battery modules by the guide elements and guide rails;Reconnecting the detachable connections for high-voltage lines, coolant lines, and control lines; checking the stability and safety of the modular battery box before releasing the vehicle for driving.

[0048] The process for the quick and safe replacement of HV battery modules advantageously minimizes vehicle downtime while maximizing uptime. The structured sequence of steps, from positioning the vehicle to uncoupling the connections and safe removal of the battery modules, through to reinsertion and final inspection, ensures precise and reliable execution of the replacement process. The ability of the guide elements and guide rails to automatically self-correct and lock the battery modules into place reduces the risk of mispositioning and damage, increasing the safety and efficiency of the system. Overall, this process contributes to reducing maintenance costs, maximizing uptime, and improving the reliability of the vehicle in daily use.

[0049] According to a preferred embodiment, it is conceivable for an autonomous vehicle to drive under the battery box, support it, and, after disconnecting the battery from the trailer, transport the battery module to the charging station. In reverse order, this vehicle could assist in reinstalling the fully charged battery segment, which would make the process even more efficient and faster.

[0050] Further features, details, and advantages of the invention will become apparent from the wording of the claims and from the following description of exemplary embodiments with reference to the drawings. They show: Fig. 1. a schematic perspective view of a trailer according to the invention with two battery boxes; Fig. 2 a schematic assembly / exploded view of a modular cage structure of a battery box of Fig. 1, with integrated battery modules; Fig. 3 a schematic detailed view of the fastening of an upper frame of the modular cage structure with support rails; Fig. 4 a schematic detailed view of a suspension device of the trailer according to the invention with a modular battery box; Fig. 5 a schematic detailed view of an attachment of mounting rails to a chassis of the trailer according to the invention.

[0051] The general in Fig. 1 with 20 is in particular a battery-electrically driven trailer 20 (not shown) for coupling to a tractor and comprises a chassis 21 formed by longitudinal and transverse beams 23, 24, which is shown in perspective in Fig. 1 is illuminated.

[0052] At least one, in particular two or three, trailer axles are arranged on an underside 22 of the chassis 21, wherein at least one axle is equipped with an electric drive unit for driving and decelerating the commercial vehicle or trailer 20. The trailer 20 further comprises at least one battery box 10, which is arranged on the underside 22 of the chassis 21 and serves to accommodate replaceable battery modules 50.

[0053] A suspension device 30 is provided that detachably connects the battery box 10 to the chassis 21, wherein the battery box 10 is mounted on the chassis 21 via the suspension device 30 in such a way that it is completely mechanically decoupled from the chassis 21. As can be seen, the chassis 21 can have cross braces 25 for additional stabilization and reinforcement, which connect the longitudinal members 23 to one another.

[0054] The battery box 10 is modular and has a modular cage structure 15 which is formed by at least one upper frame 11 for releasably fixing to the suspension device 30 and at least one parallel lower frame 12 for receiving replaceable battery modules 50 and for releasably fixing to the upper frame 11 in order to enable a quick and safe exchange of battery modules 50 from bottom to top in the vertical direction H.

[0055] How to continue using Fig. 2 and in particular by adding the Fig. 4 and Fig. 5, the suspension device 30 can comprise fixing profiles 33 which can be releasably fixed to the longitudinal members 23 on both frame sides of the chassis 21 (cf. Fig. 1 fixed position).

[0056] The fixing profiles 33 can have flat contact surfaces 33' oriented in the vertical direction H for contacting an inner profile 23' of the longitudinal beams 23 and two support arms 33" each for supporting on surfaces of mounting rails 31. Furthermore, it can be seen that the support arms 33" of the fixing profiles 33 of the suspension device 30 extend in the transverse direction Q, wherein the support arms 33" of the fixing profiles 33 can be L-shaped.

[0057] How to continue in Fig. 2 and by adding Fig. 3 and Fig. 4, the suspension device 30 can comprise at least two mounting rails 31 arranged parallel to the longitudinal members 23 on both frame sides of the chassis 21, wherein the mounting rails 31 can be designed to be applied to the fixing profiles 33 of the suspension device 30.

[0058] The suspension device 30 can further comprise at least two receiving rails 32 on each of the two frame sides of the chassis 21, which are aligned parallel to the longitudinal members 23 and can have fixing elements 37 for releasably connecting the receiving rails 32 to the upper frame 11 of the modular cage structure 15, wherein two receiving rails 32 arranged next to one another in the longitudinal direction L can have a longitudinal extension which corresponds approximately to the longitudinal extension of a mounting rail 31 arranged in the longitudinal direction L (cf. in particular Fig. 2 and Fig. 4).

[0059] In the Fig. 2 to 4 show that the mounting rails 31 and the receiving rails 32 can have U-shaped profiles, wherein the receiving rails 32 can each be arranged below the mounting rails 31 and simultaneously adjacent to one another in the longitudinal direction L. This facilitates the arrangement and enables precise assembly of the modular cage structure 15 of the battery box 10.

[0060] Fig. Figure 2 also shows a detailed view of the reinforcement elements 19 that the modular cage structure 15 of the battery box 10 may have. These reinforcement elements 19 can be used to increase the load-bearing capacity under high dynamic loads. The reinforcement elements 19 are formed by cross members projecting in the transverse direction Q, which may have recesses for stiffening and weight reduction.

[0061] Furthermore, Fig. 2, that the upper and / or lower frame 11, 12 of the modular cage structure 15 of the battery box 10 can be formed by corner and cross members 16 aligned in the transverse direction Q and by lateral longitudinal members 18 arranged in the longitudinal direction L, wherein the lateral longitudinal members 18 simultaneously function as side impact protection and the modular cage structure 15 of the battery box 10 can be adapted to accommodate battery modules 50 of different sizes.

[0062] Furthermore, Fig. 2, that the modular cage structure 15 of the battery box 10 can be designed to be adaptable in the vertical direction H and in the longitudinal direction L in order to configure the receiving structure for battery modules 50 of different sizes, wherein the modular cage structure 15 can be designed to be mirror-symmetrical to a central longitudinal axis of the chassis 21, so that identical structures for receiving exchangeable battery modules 50 can be created on both frame sides of the chassis 21.

[0063] In particular Fig. 4 shows in detail the elastic and vibration-damping silent bearings 35 of the suspension device 30. These silent bearings 35 can be used to adjust the complete mechanical decoupling of the battery box 10, wherein the silent bearings 35 can be arranged on both frame sides of the chassis 21 and designed as silent blocks to isolate vibrations and shocks and at the same time facilitate the replacement of the battery modules 50.

[0064] Furthermore, in Fig. 4 that the silent bearings 35 can dampen and isolate driving dynamic loads in the longitudinal, transverse and vertical directions L, Q, H of the trailer 20 for setting the complete mechanical decoupling of the battery box 10, wherein the silent bearings 35 can be designed and arranged such that they stabilize the battery box 10 in its position and at the same time allow mechanical movement in several axes in order to completely isolate driving dynamic loads.

[0065] As in Fig. As can be further seen in Figure 4, the silent bearings 35 can be arranged in a form-fitting manner between the mounting rails 31 and the receiving rails 32 of the suspension device 30 and can be releasably fixed to the mounting and receiving rails 31, 32 via fastening elements 13'. The silent bearings 35 can have base plates 35' on their undersides, which are supported and rest on surfaces of the receiving rails 32.

[0066] In Fig. 5 illustrates the possibility of fastening the fixing profiles 33 to the inner profiles 23' of the longitudinal members 23 by means of fastening elements 13' or screw connections.

[0067] The modular cage structure 15 of the battery box 10 can include an integrated device for temperature monitoring and cooling the battery modules 50 to ensure the optimal operating temperature. The modular cage structure 15 of the battery box 10 can be equipped with standardized interfaces that enable compatibility with different battery module types.

[0068] As in the Fig. 1 to 5, the modular cage structure 15 of the battery box 10 can comprise a plurality of replaceable battery modules 50 arranged stacked in the vertical direction H, which are received and securely held in the modular cage structure 15, wherein the modular cage structure 15 can be designed to ensure accessibility or an action space for robot arms or corresponding tools that are used for changing the battery modules 50.

[0069] Furthermore, the modular cage structure 15 and the battery modules 50 can have separable connections for high-voltage lines, coolant lines, and control lines, which enable the quick separation and connection of the replaceable battery modules 50. The upper and lower frames 11, 12 of the modular cage structure 15 can have separable interfaces with fastening elements 13 for detachable connection and complementary receiving elements, which can be formed by screw connections or quick-couplings or locking elements or connecting pins or plug connections, in order to provide the possibility of appropriately positioning and aligning the battery box 10 for a quick and safe replacement process.

[0070] As the Fig. 2, Fig. 3, Fig. 4 and Fig. 5, the modular cage structure 15 of the battery box 10 can be equipped with additional guide elements and guide rails which can ensure precise alignment and positioning of the battery modules 50 during the insertion and removal process from bottom to top or from top to bottom in the vertical direction H, wherein the guide elements for the battery modules 50 can be designed such that they can enable automatic self-correction of the battery modules 50 during the replacement process even in the case of minimal deviations in the positioning.

[0071] Furthermore, the modular cage structure 15 of the at least one battery box 10 can be provided with an additional protection system that protects cyclists and pedestrians from being driven under, in particular by being designed according to the requirements of Directive ECE-R73, wherein the battery box 10 can comprise a front and a rear attachment structure to improve aerodynamics and to additionally accommodate battery ancillaries.

[0072] Furthermore, the modular cage structure 15 of the battery box 10 can have an additional protective covering 51, in particular a sheet metal covering, which protects the replaceable battery modules 50 from environmental influences and at the same time offers electromagnetic shielding (cf. in particular Fig. 2). The protective cover 51 of the battery box 10 may comprise a lightweight metal material to optimize weight while providing adequate shielding, and may be sealed with a weather-resistant adhesive sealant at all interfaces and joints of the modular cage structure 15.

[0073] In addition, the replacement process of the battery modules 50 can be carried out manually by using tools or fully automatically by using a specially provided robot device for replacing the battery modules 50.

[0074] Finally, Fig.1, that the chassis 21 of the trailer 20 can have two battery boxes 10 spaced apart from one another with accommodated replaceable battery modules 50, which are each mounted via suspension devices 30 on both frame sides of the chassis 21, wherein the suspension devices 30 of the two battery boxes 10 on each frame side of the chassis 21 can each provide at least three fixing profiles 33 and at least four silent bearings 35 for mounting the battery boxes 10 on the longitudinal members 23 of the chassis 21.

[0075] Based on the figures and embodiments shown, a method for the quick and safe replacement of HV battery modules 50 in a commercial vehicle, in particular in a battery-electrically powered trailer 20, with a modular battery box 10 comprises the following steps: Positioning the commercial vehicle over a replacement device; Decoupling separable connections for high-voltage lines, coolant lines and control lines while the battery modules 50 are safely detached and lowered from top to bottom through the guide rails and guide elements; Removing the discharged battery modules 50 from the battery box 10; Inserting the new, charged battery modules 50 from bottom to top through the guide rails and guide elements into the modular battery box 10; Automatic self-correction and locking of the battery modules 50 by the guide elements and guide rails;Reconnecting the detachable connections for high-voltage lines, coolant lines, and control lines; Checking the stability and safety of the modular battery box 10 before releasing the vehicle for driving.

[0076] The invention is not limited to one of the embodiments described above, but can be modified in many ways.

[0077] The scope of the invention primarily extends to use in heavy commercial vehicles, particularly in the area of ​​electric trailers and electric semi-trailers. This invention is particularly relevant for applications requiring high flexibility and efficiency in energy supply and utilization, such as heavy trucks used for long-haul and long-distance freight transport.

[0078] Accordingly, the invention can be designed to address the specific requirements of this vehicle category, including the need for a robust, modular, and easily accessible battery infrastructure that meets the high performance requirements and unique logistical challenges of heavy-duty transport. Electric trailers and semi-trailers designed for transporting goods over long distances particularly benefit from the ability to swap battery modules quickly and efficiently, minimizing downtime and maximizing uptime.

[0079] Furthermore, the invention can also be used in other areas of heavy-duty transport, such as construction and agricultural vehicles, which have similar energy supply and flexibility requirements. The adaptability of the modular battery infrastructure makes the invention suitable for a wide range of application scenarios in which electric drive systems play an increasingly important role.

[0080] With the progressive electrification of road freight transport and the increasing demands for sustainability and efficiency, this invention offers a pioneering solution that can make the operation of heavy-duty vehicles more efficient and environmentally friendly. It helps overcome the challenges in range, charging times, and payload capacity associated with the introduction of electric drive systems in these vehicle categories.

[0081] All features and advantages arising from the claims, the description and the drawings, including design details, spatial arrangements and method steps, can be essential to the invention both individually and in a wide variety of combinations.

Claims

[1] Commercial vehicle, namely a battery-electric driven trailer (20) for coupling to a tractor, comprising - a chassis (21) formed by longitudinal and transverse beams (23, 24), on the underside (22) of which at least one trailer axle is arranged, wherein the at least one trailer axle is equipped with an electric drive unit for driving and decelerating the trailer (20), - at least one battery box (10) which is arranged on the underside (22) of the chassis (21) and serves to accommodate replaceable battery modules (50), and - a suspension device (30) which detachably connects the battery box (10) to the chassis (21), wherein the suspension device (30) has elastic and vibration-damping silent bearings (35) for achieving a mechanical decoupling of the battery box (10) from the chassis (21), wherein the battery box (10) is connected to the chassis (21) only via the silent bearings (35) and is mechanically decoupled from the chassis (21), wherein the battery box (10) is of modular design and has a modular cage structure (15) which is formed by at least one upper frame (11) for detachably fixing to the suspension device (30) and at least one parallel lower frame (12) for receiving replaceable battery modules (50) and for detachably fixing to the upper frame (11), in order to enable a quick and safe exchange of battery modules (50) from bottom to top or from top to bottom. make possible, characterized byin that the suspension device (30) comprises fixing profiles (33) which are releasably fixed to the longitudinal members (23) on both frame sides of the chassis (21), wherein the fixing profiles (33) have flat contact surfaces (33') aligned in the vertical direction (H) for contacting an inner profile (23') of the longitudinal members (23) and each have two support arms (33") for resting on surfaces of mounting rails (31). [2] Commercial vehicle according to claim 1, characterized by that the support arms (33") of the fixing profiles (33) of the suspension device (30) extend in the transverse direction (Q), wherein the support arms (33") of the fixing profiles (33) are L-shaped. [3] Commercial vehicle according to one of the preceding claims, characterized bythat the suspension device (30) comprises at least two mounting rails (31) arranged parallel to the longitudinal members (23) on both frame sides of the chassis (21), wherein the mounting rails (31) are designed to be applied to fixing profiles (33) of the suspension device (30). [4] Commercial vehicle according to one of the preceding claims, characterized by in that the suspension device (30) comprises at least two receiving rails (32) on each of the two frame sides of the chassis (21), which are aligned parallel to the longitudinal members (23) and have fixing elements (37) for releasably connecting the receiving rails (32) to the upper frame (11) of the modular cage structure (15), wherein two receiving rails (32) arranged next to one another in the longitudinal direction (L) have a longitudinal extent which corresponds to the longitudinal extent of a mounting rail (31) arranged in the longitudinal direction (L). [5] Commercial vehicle according to claims 3 and 4, characterized by that the mounting rails (31) and the receiving rails (32) have U-shaped profiles, wherein the receiving rails (32) are each arranged below the mounting rails (31) and at the same time next to one another in the longitudinal direction (L). [6] Commercial vehicle according to one of the preceding claims, characterized by that the silent bearings (35) are arranged on both sides of the chassis (21) and are designed as silent blocks in order to isolate vibrations and shocks and at the same time to facilitate the replacement of the battery modules (50). [7] Commercial vehicle according to one of the preceding claims, characterized bythat the silent bearings (35) for setting the complete mechanical decoupling of the battery box (10) dampen and isolate driving dynamic loads in the longitudinal, transverse and vertical directions (L, Q, H) of the trailer (20), wherein the silent bearings (35) are designed and arranged such that they stabilize the battery box (10) in its position and at the same time allow mechanical movement in several axes in order to completely isolate driving dynamic loads. [8] Commercial vehicle according to claims 3 and 4, characterized by that the silent bearings (35) are arranged in a form-fitting manner between the mounting rails (31) and the receiving rails (32) of the suspension device (30) and can be detachably and non-positively fixed to the mounting and receiving rails (31, 32) via fastening elements (13'), wherein the silent bearings (35) have base plates (35') on their undersides which are supported and rest on surfaces of the receiving rails (32). [9] Commercial vehicle according to one of the preceding claims, characterized by in that the modular cage structure (15) of the battery box (10) is provided with additional reinforcing elements (19) in order to increase the load-bearing capacity under high dynamic loads, wherein the additional reinforcing elements (19) are formed by cross members (16) projecting in the transverse direction (Q) and having recesses for stiffening and weight reduction. [10] Commercial vehicle according to one of the preceding claims, characterized bythat the upper and / or lower frame (11, 12) of the modular cage structure (15) of the battery box (10) are formed by corner and cross members (16) aligned in the transverse direction (Q) and by lateral longitudinal members (18) arranged in the longitudinal direction (L), wherein the lateral longitudinal members (18) simultaneously function as side impact protection and the modular cage structure (15) of the battery box (10) is designed to be adaptable in order to be able to accommodate battery modules (50) of different sizes and to use different battery capacities. [11] Commercial vehicle according to one of the preceding claims, characterized byin that the modular cage structure (15) of the battery box (10) is designed to be adaptable in the vertical direction (H) and in the longitudinal direction (L) in order to configure the receiving structure for battery modules (50) of different sizes, wherein the modular cage structure (15) is designed to be mirror-symmetrical to a central longitudinal axis of the chassis (21), so that identical structures for receiving exchangeable battery modules (50) are created on both frame sides of the chassis (21). [12] Commercial vehicle according to one of the preceding claims, characterized by in that the modular cage structure (15) of the battery box (10) has an integrated device for temperature monitoring and cooling the battery modules (50) in order to ensure the optimum operating temperature, wherein the modular cage structure (15) of the battery box (10) is equipped with standardized interfaces which enable compatibility with different battery module types. [13] Commercial vehicle according to one of the preceding claims, characterized by in that the modular cage structure (15) of the battery box (10) comprises a plurality of replaceable battery modules (50) arranged stacked in the vertical direction (H), which are accommodated in the modular cage structure (15) and are held securely, wherein the modular cage structure (15) is designed to ensure an action space for robot arms or tools which are used for changing the battery modules (50). [14] Commercial vehicle according to one of the preceding claims, characterized byin that the modular cage structure (15) and the battery modules (50) have separable connections for high-voltage lines, coolant lines and control lines, which enable the rapid separation and connection of the replaceable battery modules (50), wherein the upper and lower frames (11, 12) of the modular cage structure (15) have separable interfaces with fastening elements (13) for detachable connection and complementary receiving elements which are formed by screw connections or quick couplings or locking elements or connecting pins or plug connections in order to offer the possibility of positioning and aligning the battery box (10) for a quick and safe replacement process. [15] Commercial vehicle according to one of the preceding claims, characterized byin that the modular cage structure (15) of the battery box (10) is equipped with additional guide elements and guide rails which ensure precise alignment and positioning of the battery modules (50) during the insertion and removal process from bottom to top or from top to bottom in the vertical direction (H), wherein the guide elements for the battery modules (50) are designed in such a way that they enable automatic self-correction of the battery modules (50) during the replacement process even in the case of minimal deviations in the positioning. [16] Commercial vehicle according to one of the preceding claims, characterized byin that the modular cage structure (15) of the at least one battery box (10) is provided with an additional protection system which protects cyclists and pedestrians from being driven under by being designed in accordance with the requirements of Directive ECE-R73, wherein the battery box (10) comprises a front and a rear attachment structure for improving aerodynamics and for additionally accommodating battery ancillary units. [17] Commercial vehicle according to one of the preceding claims, characterized byin that the modular cage structure (15) of the battery box (10) has an additional protective covering (51) which protects the replaceable battery modules (50) from environmental influences and at the same time offers electromagnetic shielding, wherein the protective covering (51) of the battery box (10) comprises a light metal material in order to optimize the weight and at the same time offer sufficient shielding, and wherein the protective covering (51) of the battery box (10) is sealed with a weather-resistant adhesive sealant at all intersections and connection points of the modular cage structure (15). [18] Commercial vehicle according to one of the preceding claims, characterized by that the replacement process of the battery modules (50) is carried out manually by using tools or fully automatically by using a robot device for replacing the battery modules (50). [19] Commercial vehicle according to one of the preceding claims, characterized byin that the chassis (21) of the trailer (20) has two battery boxes (10) spaced apart from one another with accommodated replaceable battery modules (50), which are each mounted via suspension devices (30) on both frame sides of the chassis (21), wherein the suspension devices (30) of the two battery boxes (10) on each frame side of the chassis (21) each have at least three fixing profiles (33) and at least four silent bearings (35) for mounting the battery boxes (10) on the longitudinal members (23) of the chassis (21). [20] Method for the quick and safe replacement of HV battery modules (50) in a battery-electrically powered trailer (20), with a modular battery box (10) according to one of the preceding claims, comprising the steps: a) positioning the trailer (20) over an exchange device, b) decoupling separable connections for high-voltage lines, coolant lines and control lines while the battery modules (50) are safely released and lowered from top to bottom through the guide rails and guide elements; c) removing the discharged battery modules (50) from the battery box (10), d) Inserting the new, charged battery modules (50) from bottom to top through the guide rails and guide elements into the modular battery box (10), e) Automatic self-correction and locking of the battery modules (50) by the guide elements and guide rails, f) Reconnecting the separable connections for high-voltage lines, coolant lines and control lines, g) Checking the stability and safety of the modular battery box (10) before releasing the vehicle for driving operation.

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