ENERGY MODULE FOR A COMMERCIAL VEHICLE

DE502019014479D1Active Publication Date: 2026-03-26MAN TRUCK & BUS SE
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Patent Information

Authority / Receiving Office
DE · DE
Patent Type
Patents
Current Assignee / Owner
Filing Date
2019-08-22
Publication Date
2026-03-26

AI Technical Summary

Technical Problem

The installation of high-voltage components in fully or partially electrified commercial vehicles poses significant safety risks due to improper assembly and assembly conflicts, necessitating late installation, which complicates the manufacturing process and increases safety hazards for operators and road users.

Method used

An energy module comprising high-voltage energy storage devices and a cooling system, supported by a detachable structure that can be pre-assembled and tested independently, allowing for safe and efficient integration with the vehicle frame, enabling separate commissioning and testing, and accommodating expansion and quick disassembly.

Benefits of technology

The energy module facilitates safe and efficient assembly of high-voltage components, reduces assembly time, and allows for independent testing and expansion, enhancing safety and reducing mechanical and electrical connections, while protecting components from vibrations and crashes.

✦ Generated by Eureka AI based on patent content.
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Description

[0001] The invention relates to an energy module for a commercial vehicle, preferably for a truck or a bus.

[0002] When assembling a fully or partially electrified commercial vehicle, the installation of high-voltage components is significantly higher than with conventional vehicles due to occupational safety requirements and the stringent qualification demands placed on employees. For these reasons, the energy-carrying components should be installed on the vehicle as late as possible, which can lead to assembly conflicts. The energy components must be mechanically and electrically assembled and installed without any potential difference. Improper assembly, especially of high-voltage components, poses an enormous safety risk in practical use, both during the manufacturing process and for the vehicle operator, as well as for road users. Furthermore, the passive safety of the high-voltage components in the event of a crash is a crucial consideration.

[0003] German patent application DE 10 2017 004 162 A1 discloses an electric or hybrid bus comprising a floor structure and a battery module structure. The floor structure is arranged between a front axle segment and a rear axle segment of the bus and is connected to both segments. The floor structure is a load-bearing structure of the bus. The battery module structure comprises a plurality of battery modules and can be reversibly detached from the underside of the bus and fixed to the floor structure. The floor structure includes a battery cooling unit for dissipating heat energy from the battery modules.

[0004] From DE 10 2013 004 837 A1, an energy supply module for a commercial vehicle is known. The energy supply module can be accommodated in a rear-mounted housing of a drive module of the commercial vehicle. In one embodiment, the energy supply module includes battery stacks for storing electrical current.

[0005] DE 10 2011 109024 A1 relates to an electric drive module for a commercial vehicle with an electric or hybrid drive. The drive module comprises at least a battery pack, a support frame for the battery pack that can be attached to the vehicle body, and a cooling device for temperature control of the electrical components.

[0006] WO 2017 / 076980 A1 concerns a floor-mounted and driverless heavy-duty transport vehicle for ISO containers, with a drive system and a battery module to supply the drive system with electrical energy, wherein the battery module has a support frame and a battery.

[0007] DE 10 2013 001473 A1 relates to a modular unit for a commercial vehicle, such as a bus or a truck. The modular unit comprises a support frame that forms a mounting space and serves to attach it to the commercial vehicle. The mounting space is used to hold components. These components include a fuel tank and an electric drive energy storage device.

[0008] The invention is based on the objective of creating an alternative and / or improved energy module for a motor vehicle.

[0009] The problem is solved by the features of independent claim 1. Advantageous further developments are specified in the dependent claims and the description.

[0010] The invention provides an energy module for a commercial vehicle, preferably a truck or a bus. The energy module comprises several high-voltage energy storage devices and a cooling system for (e.g., actively) cooling the high-voltage energy storage devices. The energy module has a support structure that carries the several high-voltage energy storage devices and the cooling system and is designed to be attached from below to a vehicle frame (e.g., ladder frame) of the commercial vehicle (e.g., detachably).

[0011] The energy module offers the advantage of integrating high-voltage electrical energy storage with other essential high-voltage and low-voltage components of the commercial vehicle, such as the cooling system. The entire energy module can be mounted and functionally tested outside the vehicle. All components of the energy module are mechanically connected, electrical connections are wired, and all temperature-controlled components in the cooling system are integrated.

[0012] The energy module concept is infinitely expandable. Depending on requirements, additional energy storage units can be added as needed, and / or one of the energy storage units can be replaced, for example, by a range extender. Assembling the energy module independently of the rest of the commercial vehicle offers advantages due to the necessary high-voltage qualifications of the workers and the safety requirements. This may also allow for different cycle times. Commissioning and testing of the energy module can be carried out separately from the assembly line, which is advantageous due to the need to consider complex or specialized high-voltage testing equipment. The energy module supports a localization concept for modules and / or complete vehicles at different locations. High-voltage expertise can be concentrated within the energy module, independent of the assembly process.This results in a short assembly time to the base vehicle with few mechanical and electrical connections and simple integration into the assembly line, as only one module is mounted to the vehicle from below ("electrical marriage"). Furthermore, it allows for expansion depending on the vehicle application without structural modifications to the rest of the vehicle. In addition, quick disassembly is possible for servicing.

[0013] In one embodiment, the support structure elastically mounts the multiple high-voltage energy storage devices and / or the cooling system from a base frame of the support structure and / or decouples them. This protects the electrical components from harmful vibrations during driving and from damage in the event of a crash.

[0014] In another embodiment, the cooling system has a refrigeration cycle (e.g. with phase change of the refrigerant; e.g. with compressor, condenser, expansion valve and evaporator) and / or a liquid cooling cycle.

[0015] The liquid cooling circuit can be expediently connected to the evaporator of the refrigeration circuit for heat transfer and / or have heat exchangers for cooling the multiple high-voltage energy storage devices.

[0016] In another embodiment, the cooling system is designed to cool one or more additional electrical components, preferably high-voltage components (e.g., DC-DC converters and / or high-voltage power distributors, etc.) of the energy module, in addition to the multiple high-voltage energy storage devices.

[0017] In one embodiment, the cooling system has a cooling interface for connection to components to be cooled outside the energy module.

[0018] In another embodiment, the cooling system, preferably a refrigerant compressor, valves and / or actuators of the cooling system, is driven by low-voltage electrical energy from the energy module.

[0019] It is possible that, in addition to the multiple high-voltage energy storage devices and the cooling system, the energy module includes further high-voltage and / or low-voltage electrical components, which are preferably supported by the supporting structure, preferably elastically and / or decoupled from a base frame of the supporting structure. With each additional electrical component, the functional integration of the energy module increases.

[0020] In one version, the energy module features a high-voltage power distributor.

[0021] In another embodiment, the energy module includes a heater, preferably a high-voltage heater, e.g. for heating the several high-voltage energy storage devices.

[0022] In one embodiment, the energy module has at least one DC-DC converter (e.g., two high-voltage to 12V converters) for converting between a high-voltage DC voltage and a low-voltage DC voltage.

[0023] In another embodiment, the energy module has a high-voltage interface for supplying high-voltage components outside the energy module.

[0024] In one embodiment, the energy module has at least one low-voltage energy storage device (e.g., two 12V energy storage devices).

[0025] In another embodiment, the energy module has an on-board charger for externally charging the multiple high-voltage energy storage devices.

[0026] In one embodiment, the energy module includes a steering pump, preferably a low-voltage steering pump, for power steering of the commercial vehicle.

[0027] In another version, the energy module features a range extender (e.g., generator with combustion engine or fuel cell).

[0028] It is advantageous for the high-voltage power distributor, the heater, the at least one DC-DC converter, the high-voltage interface, the on-board charger and / or the range extender to be electrically connected to the multiple high-voltage energy storage devices, e.g. via the high-voltage power distributor.

[0029] In one embodiment, the support structure carries the high-voltage power distributor, the heater, the at least one DC-DC converter, the at least one low-voltage energy storage device, the on-board charger, the power steering pump, and / or the range extender. Preferably, the support structure elastically and / or decouples the high-voltage power distributor, the heater, the at least one DC-DC converter, the at least one low-voltage energy storage device, the on-board charger, the power steering pump, and / or the range extender from a base frame of the support structure.

[0030] In another embodiment, the cooling system, the high-voltage power distribution unit, the heater, the at least one DC-DC converter, the at least one low-voltage energy storage device, the on-board charger, the power steering pump, the high-voltage interface, and / or the range extender are arranged at least partially (e.g., directly or indirectly) on or above the multiple high-voltage energy storage devices. Such an arrangement can be advantageous, for example, for reasons of installation space and assembly.

[0031] In another embodiment, the multiple high-voltage energy storage devices are arranged on the floor and / or next to each other in the supporting structure.

[0032] In one embodiment, the energy module is pre-assembled and electrically wired to enable independent electrical functional testing. Alternatively or additionally, the multiple high-voltage energy storage devices, the cooling system, a high-voltage power distributor, a heater, at least one DC-DC converter, at least one low-voltage energy storage device, an on-board charger, a power steering pump, a high-voltage interface, and / or a range extender are electrically wired within the energy module in a way that allows for independent testing.

[0033] In another embodiment, the cooling system is pre-assembled and piped in the energy module to enable independent cooling function testing.

[0034] In one embodiment, the supporting structure has a base frame and / or several support units, which are preferably elastically mounted on the base frame.

[0035] In a further training course, the basic frame is designed in a box-shaped and / or cage-shaped form and / or the several support units are designed in a box-shaped and / or cage-shaped form.

[0036] In one embodiment, the multiple support units are incorporated into the base frame and preferably arranged side by side.

[0037] In another variant, the base frame has a number of fastening devices on its upper side for attaching the base frame to the vehicle frame of the commercial vehicle.

[0038] In one embodiment, the multiple support units carry the multiple high-voltage energy storage units, the cooling system, the high-voltage power distributor, the heater, the at least one DC-DC converter, the at least one low-voltage energy storage unit, the on-board charger, the steering pump, the high-voltage interface and / or the range extender.

[0039] In one embodiment, the multiple support units have two outer support units, which are preferably arranged on the outer longitudinal sides of the energy module, and / or an inner support unit arranged between them.

[0040] The inner support unit can be advantageously positioned centrally between the outer support units.

[0041] In this advanced version, the inner support unit carries at least one high-voltage electrical component, distinct from the multiple high-voltage energy storage devices. Alternatively or additionally, the inner support unit carries the high-voltage power distributor, at least one DC-DC converter, the on-board charger, the heater, and / or the high-voltage interface. The electrical components housed within the inner support unit are specially protected, which is particularly advantageous for sensitive high-voltage components.

[0042] In a further development, the outer support units carry at least one low-voltage electrical component, preferably the steering pump, the cooling system and / or the at least one low-voltage energy storage device.

[0043] In one embodiment, the inner support unit carries at least one electrical high-voltage component that differs from the multiple high-voltage energy storage devices (e.g., the high-voltage power distributor, the at least one DC-DC converter, the heater, the on-board charger and / or the high-voltage interface) and that is arranged in a vertical direction upwards, at least partially projecting over the central support unit, preferably for protected arrangement between main longitudinal members of the vehicle frame.

[0044] In another embodiment, the supporting structure, preferably a base frame of the supporting structure, has a crash structure on two oppositely facing outer sides (e.g. longitudinal outer sides of the supporting structure, the base frame and / or the energy module) which absorbs impact energy in the event of a side impact under predetermined plastic deformation, preferably without affecting the multiple support units.

[0045] In a further development, the crash structure is formed by a three-dimensional profile structure, preferably a trapezoidal profile structure, preferably made of sheet metal and / or plastic, and / or by a metal foam.

[0046] In one embodiment, the supporting structure, preferably a base frame of the supporting structure, has an underride protection element on at least one outer side, preferably a front and a rear side of the supporting structure and / or the base frame, preferably in the form of an underride protection plate arranged at an inclination (e.g. inclined to a horizontal axis and / or a vertical axis) and located on a lower edge of the outer side.

[0047] The invention also relates to a commercial vehicle, preferably a truck or a bus, comprising the energy module as disclosed herein. The energy module is attached from below to a vehicle frame, preferably a ladder frame, of the commercial vehicle, preferably between a front axle and a rear axle of the commercial vehicle.

[0048] It is also possible to use the device as disclosed herein for other motor vehicles, e.g. off-road vehicles, etc.

[0049] The preferred embodiments and features of the invention described above can be combined in any way desired. Further details and advantages of the invention are described below with reference to the accompanying drawings. These show: Figure 1 is a perspective view of a purely schematic arrangement of an energy module on a vehicle frame according to the present disclosure; Figure 2 is a perspective view of an energy module according to the present disclosure; and Figure 3 is a perspective view of a support device for an energy module according to the present disclosure.

[0050] The embodiments shown in the figures are at least partially identical, so that similar or identical parts are provided with the same reference numerals and, to avoid repetition, reference is also made to the description of the other embodiments or figures for their explanation.

[0051] The Figure 1 Figure 10 schematically shows an energy module 10. The energy module 10 is mounted from below to a vehicle frame 12 of a commercial vehicle. The commercial vehicle can be, for example, a truck or a bus. Preferably, the commercial vehicle can be an electric commercial vehicle powered solely by electrical energy, or a hybrid commercial vehicle that can also be powered by electrical energy.

[0052] The energy module 10 is designed to provide electrical energy to power an electric drive unit of the commercial vehicle located outside the energy module 10. In addition to electrical energy storage devices, the energy module 10 also integrates essential high-voltage and low-voltage components of the commercial vehicle.

[0053] The vehicle frame 12 can have two parallel, spaced-apart main longitudinal members 14 and several cross members 16 extending between the main longitudinal members 14. As shown in Figure 1, the energy module 10 can be attached to the vehicle frame 12 from below, preferably rigidly. By mounting it under the vehicle frame 12, the energy module 10 is independent of the configuration of the vehicle frame 12. Specifically, the energy module 10 can be attached externally to the main longitudinal members 14 and / or from below to the cross members 16, preferably detachably, for example by means of screws. The energy module 10 is arranged between a front axle 18 and a rear axle 20 of the commercial vehicle.

[0054] The Figures 2 and 3 show an exemplary embodiment of the energy module 10. Figure 2 The diagram shows part of a supporting structure 22 of the energy module 10. Figure 3The supporting structure 22 of the energy module 10 is shown in its entirety, with the electrical components of the energy module 10 in Figure 3 They have been omitted for the sake of clarity.

[0055] The supporting structure 22 has a base frame 24 and several support units 26.

[0056] The base frame 24 is designed as an outer frame and is preferably box-shaped or cage-shaped and open at the top. The multiple support units 26 are also preferably box-shaped or cage-shaped. The multiple support units 26 are received in the base frame 24. Preferably, the multiple support units 26 are elastically mounted and thus decoupled from the base frame 24. For example, the support units 26 are supported on a base of the base frame 24 via elastic bearings, such as rubber bearings.

[0057] In the illustrated embodiment, three support units 26 are arranged side by side and aligned with respect to a longitudinal direction of the commercial vehicle. When the energy module 10 is mounted to the vehicle frame 12, the inner or central support unit 26 is located directly below the vehicle frame 12. The two outer support units 26 are each located on both longitudinal outer sides of the commercial vehicle.

[0058] The electrical components of the energy module 10 are housed in the support units 26. Due to the elastic mounting of the support units 26, vibrations during driving have a less detrimental effect on the electrical components. Furthermore, the electrical components are better protected, for example, in the event of a side impact on the energy module 10, as they can move to a limited extent in one direction of the side impact.

[0059] The base frame 24 forms a protective structure to safeguard the support units 26 and the electrical components housed therein in the event of accidents, particularly side impacts. This protective structure is created by a frame-like arrangement of outer beams (outer crossbeams and longitudinal beams) 28, which secure the support units 26 towards the front, rear, right longitudinal side, and left longitudinal side. Furthermore, several inner crossbeams 30 are arranged, which directly support the outer beams 28 of the longitudinal side against the vehicle frame 12. One bottom side of the base frame 24 is formed as a lattice frame, for example, from flat sheet metal profiles or strips.

[0060] Furthermore, a crash structure 32 can be arranged on the longitudinal outer sides of the base frame 24 (see Figure 2 For clarity, crash structure 32 is only shown in Figure 2The crash structure 32 is shown for one of the two longitudinal outer sides of the base frame 24. It is designed to absorb impact energy in the event of a side impact, for example, of a passenger car, under a predetermined plastic deformation. The load-bearing units 26 are not affected in this process. The crash structure 32 can, for example, be formed from a trapezoidal sheet metal structure, as shown. However, it is also possible, for example, for the crash structure 32 to be formed from another three-dimensional profile structure, preferably made of sheet metal and / or plastic, and / or from a metal foam.

[0061] In the event of a side impact, the impact energy can thus be dissipated in stages. First, the crash structure 32 deforms plastically on the corresponding longitudinal outer side of the impact, thereby dissipating impact energy. The remaining portion is transferred via the outer supports 28 and the inner cross members 30 into the vehicle frame 12. The entire energy module 10 can also dissipate via the progressively increasing energy dissipation beneath the vehicle frame 12. Any minor deformation of the base frame 24 has no effect on the electrical components, as these are elastically mounted within the base frame 24 via the support units 26 and can therefore move (to a limited extent) within the base frame 24.

[0062] Several fastening devices 34 are arranged on the upper surface of the base frame 24. The fastening devices 34 are designed to attach the base frame 24, and thus the entire energy module 10, directly and / or indirectly to the vehicle frame 12, preferably detachably, for example by means of screws. For example, two fastening devices 34 can be arranged at the free ends of the inner cross members 30 for direct attachment to the longitudinal outer surfaces of the vehicle frame 12. Two further fastening devices 34 each can be arranged on a front and a rear side of the base frame 24 for indirect attachment to the vehicle frame 12, for example via intermediate mounting brackets.

[0063] An underride guard element 39 can be arranged on the underside of the base frame 24, both on the front and rear sides. The underride guard element 39 can be inclined to a horizontal axis and a vertical axis and may, for example, be in the form of an underride guard plate. The underride guard elements 39 are arranged on a lower edge of the front and rear sides of the energy module 10. The underride guard elements 39 extend along the entire width of the energy module 10.

[0064] As in Figure 2As shown, the energy module 10 comprises several electrical components. In particular, the energy module 10 comprises several high-voltage energy storage devices 36 and a cooling system 38. In addition to the high-voltage energy storage devices 36 and the cooling system 38, the energy module 10 can have further electrical components to increase functional integration. For example, the energy module 10 can also have a high-voltage power distributor 40, a heater 42, at least one DC-DC converter 44, at least one low-voltage energy storage device 46, an on-board charger 48, a power steering pump 50, and / or a high-voltage interface 52, as shown in Figure 2 is shown.

[0065] The high-voltage energy storage units 36 are arranged at ground level in the support units 26 and are thus elastically mounted relative to the base frame 24. The high-voltage energy storage units 36 are designed, for example, for storing high-voltage direct current electrical energy. Depending on the requirements, the high-voltage energy storage units 36 can be connected at least partially in parallel and / or in series.

[0066] The remaining electrical components of the energy module 10, such as the cooling system 38, the high-voltage power distributor 40, the heater 42, the at least one DC-DC converter 44, the at least one low-voltage energy storage device 46, the on-board charger 48, the power steering pump 50, and / or the high-voltage interface, are distributed within the support units 26. Preferably, these electrical components are arranged at least partially above the high-voltage energy storage devices 36, e.g., mounted directly or indirectly on them.

[0067] The cooling system 38 is designed for actively cooling the high-voltage energy storage units 36. The cooling system 38 can include a refrigeration circuit with phase change of the refrigerant and a liquid cooling circuit cooled by this refrigerant. For example, the refrigeration circuit can include a compressor, a condenser, an expansion valve, and an evaporator. For example, the evaporator can be used to cool the liquid cooling circuit, which can include several heat exchangers for the multiple high-voltage energy storage units 36 and, if applicable, other electrical components of the energy module 10 that require cooling. The cooling system 38, in particular the compressor, actuators, and valves thereof, can be electrically driven, e.g., with low-voltage electrical energy from the low-voltage energy storage units 46. The refrigeration circuit, in particular the compressor, the condenser, the expansion valve, and / or the evaporator, can be arranged in one of the outer support units 26.In addition to the multiple high-voltage energy storage devices 36, the cooling system 38 can cool one or more other electrical components, preferably high-voltage components (e.g., DC-DC converters 44 and / or high-voltage power distributors 40, etc.), of the energy module 10 that require temperature control. Furthermore, the cooling system 38 can have an external cooling interface through which components of the commercial vehicle outside the energy module 10 that require cooling can be connected to the cooling system 38.

[0068] The high-voltage power distributor 40 provides a variety of high-voltage connections for a corresponding variety of high-voltage components (e.g. heater 42, DC-DC converter 44, on-board charger, range extender, etc.) of the high-voltage on-board system to enable an electrically conductive connection with the high-voltage energy storage devices 36.

[0069] The heater 42 can preferably be configured as a high-voltage heater. The heater 42 can be used to heat the high-voltage energy storage units 36 at low ambient temperatures. The heater 42 can be supplied with electrical energy from the high-voltage energy storage units 36 via the high-voltage power distributor 40.

[0070] The at least one DC-DC converter 44 is designed to convert the high-voltage DC voltage of the high-voltage electrical system to the low-voltage DC voltage of a low-voltage electrical system. For example, two DC-DC converters 44 can be provided to convert the high-voltage DC voltage to a 12 V DC voltage each, in order to supply a 24 V electrical system of the commercial vehicle. In particular, the low-voltage energy storage devices 46 can be charged in this way.

[0071] The low-voltage energy storage units 46 are designed to store low-voltage electrical energy for supplying the low-voltage electrical system. For example, two 12 V energy storage units 46 can be used to supply a 24 V electrical system.

[0072] The on-board charger (OBC) 48 is used for externally charging the multiple high-voltage energy storage devices 36. The on-board charger 48 can be electrically connected to a DC charging socket for connecting an external charging cable. The on-board charger 48 can, for example, be located below one of the DC-DC converters 44.

[0073] The steering pump 50 can be assigned to a power steering system of the commercial vehicle. The steering pump 50 can preferably be designed as a low-voltage steering pump.

[0074] The high-voltage electrical interface 52 of the energy module 10 can be used, for example, to supply electrical energy to an electric drive unit or its inverter located outside the energy module 10. The energy module 10 can also have one or more low-voltage interfaces for supplying low-voltage electrical components of the commercial vehicle located outside the energy module 10. For example, the low-voltage interfaces can be connected to a main wiring harness on the vehicle frame side of the commercial vehicle.

[0075] It is also possible that the energy module 10 optionally includes a range extender (not shown). The range extender is an additional component in an electric vehicle that increases its range. The range extender can provide electrical energy for charging the high-voltage energy storage unit 36. For example, the range extender can be designed as a combination of an internal combustion engine and a generator, or as a fuel cell powered by hydrogen or methanol.

[0076] Sensitive high-voltage components can be particularly well protected by the two outer support units 26 within the inner support unit 26. As shown, the high-voltage power distributor 40, the DC-DC converters 44, the on-board charger 48, and the high-voltage interface 52 can be housed in the inner support unit 26. Additional and / or alternative electrical components, especially high-voltage components, can be arranged in the inner support unit 26. The cooling system 38, the heater 42, the low-voltage energy storage devices 46, and / or the power steering pump 50, for example, can be arranged in the outer support units 26.

[0077] The inner support unit 26 is not only specially protected between the two outer support units 26. Additionally, the electrical components housed in the inner support unit 26 can extend at least partially beyond the inner support unit 26 in a vertical direction, i.e., project upwards from the inner support unit 26. These electrical components thus extend into a space which, in the state of the energy module 10 being mounted on the vehicle frame 12, is specially protected between the main longitudinal beams 14 (see Figure 1 In the exemplary embodiment, this is implemented, for example, for the high-voltage power distributor 40 and the DC-DC converters 44. Additional and / or alternative electrical components, in particular high-voltage components, can be arranged projecting vertically in the inner support unit 26.

[0078] The invention is not limited to the preferred embodiments described above. Rather, a multitude of variants and modifications are possible, which also make use of the inventive concept and therefore fall within the scope of protection. In particular, the invention also claims protection for the subject matter and the features of the dependent claims independently of the referenced claims. In particular, the features of independent claim 1 are disclosed independently of one another. In addition, the features of the dependent claims are also disclosed independently of all features of independent claim 1 and, for example, independently of the features relating to the presence and / or configuration of the multiple high-voltage energy storage devices, the cooling system, and / or the support structure of independent claim 1. Reference symbol list

[0079] 10 Energy module 12 Vehicle frame 14 Main longitudinal member 16 Cross member 18 Front axle 20 Rear axle 22 Support structure 24 Base frame 26 Support units 28 Outer beam 30 Inner cross member 32 Crash structure 34 Fastening device 36 High-voltage energy storage 38 Cooling system 39 Underride protection element 40 High-voltage power distributor 42 Heater 44 DC-DC converter 46 Low-voltage energy storage 48 On-board charger 50 Power steering pump 52 High-voltage interface

Claims

1. An energy module (10) for a utility vehicle, preferably a lorry or a bus, comprising: a plurality of high-voltage energy storages (36); a cooling system (38) for cooling the high-voltage energy storages (36); and a support structure (22) that supports the plurality of high-voltage energy storages (36) and the cooling system (38) and is configured to be attached from below to a vehicle frame (12) of the utility vehicle; wherein the support structure (22), preferably a base frame (24) of the support structure (22), comprises, on two outer sides facing away from each other, a crash structure (32) that absorbs impact energy in an event of a side impact under predetermined plastic deformation, preferably without affecting the plurality of support units (26).

2. The energy module (10) according to claim 1, wherein: the support structure (22) supports the plurality of high-voltage energy storages (36) and / or the cooling system (38) in an elastic and / or decoupled manner from a base frame (24) of the support structure (22).

3. The energy module (10) according to claim 1 or claim 2, wherein: the cooling system (38) comprises a refrigeration circuit and / or a liquid cooling circuit; and / or the cooling system (38) is configured to cool, in addition to the plurality of high-voltage energy storages (36), one or more other electrical components, preferably high-voltage components, of the energy module (10); and / or the cooling system (38) comprises a cooling interface for connection to components outside the energy module (10) that are to be cooled; and / or the cooling system (38) is powered by low-voltage electric energy from the energy module (10).

4. The energy module (10) according to any one of the preceding claims, further comprising: a high-voltage power distributor (40); and / or a heater (42), preferably a high voltage heater; and / or at least one DC-DC converter (44) for converting between a high-voltage DC voltage and a low-voltage DC voltage; and / or a high-voltage interface (52) for supplying high-voltage components outside the energy module (10).

5. The energy module (10) according to any one of the preceding claims, further comprising: at least one low-voltage energy storage (46); and / or an on-board charger (48) for externally charging the plurality of high-voltage energy storages (36); and / or a steering pump (50), preferably a low-voltage steering pump, for power steering of the utility vehicle; and / or a range extender.

6. The energy module (10) according to claim 4 or claim 5, wherein: the support structure (22) supports the high-voltage power distributor (40), the heater (42), the at least one DC-DC converter (44), the at least one low-voltage energy storage (46), the on-board charger (48), the steering pump (50) and / or the range extender, and is preferably mounted elastically and / or decoupled from a base frame (24) of the support structure (22).

7. The energy module (10) according to any one of claims 4 to 6, wherein: the cooling system (38), the high-voltage power distributor (40), the heater (42), the at least one DC-DC converter (44), the at least one low-voltage energy storage (46), the on-board charger (48), the steering pump (50), the high-voltage interface (52) and / or the range extender are at least partially arranged on or above the plurality of high-voltage energy storages (36); and / or the plurality of high-voltage energy storages (36) are arranged on a bottom-side and / or next to each other in the support structure (22).

8. The energy module (10) according to any one of the preceding claims, wherein: the energy module (10) is pre-assembled and electrically wired to enable independent electrical functional testing; and / or the plurality of high-voltage energy storages (36), the cooling system (38), a high-voltage power distributor (40), a heater (42), at least one DC-DC converter (44), at least one low-voltage energy storage (46), an on-board charger (48), a steering pump (50), a high-voltage interface (52) and / or a range extender are electrically wired in the energy module (10) in such a way that they can be tested independently; and / or the cooling system (38) is pre-assembled and piped in the energy module (10) to enable independent testing of a cooling function.

9. The energy module (10) according to any one of the preceding claims, wherein: the support structure (22) comprises a base frame (24) and a plurality of support units (26) which are elastically supported on the base frame (24), wherein preferably: the base frame (24) is configured in a box-shaped and / or cage-shaped manner; and / or the plurality of support units (26) are configured in a box-shaped and / or cage-shaped manner; and / or the plurality of support units (26) are received in the base frame (24), preferably arranged next to one another; and / or the base frame (24) comprises a plurality of fastening devices (34) on its upper side for fastening the base frame (24) to the vehicle frame (12) of the utility vehicle.

10. The energy module (10) according to claim 9, wherein: the plurality of support units (26) support the plurality of high-voltage energy storages (36), the cooling system (38), the high-voltage power distributor (40), the heater (42), the at least one DC-DC converter (44), the at least one low-voltage energy storage (46), the on-board charger (48), the steering pump (50), the high-voltage interface (52) and / or the range extender.

11. The energy module (10) according to claim 9 or claim 10, wherein the plurality of support units (26) comprise two outer support units (26) arranged on outer longitudinal sides of the energy module (10) and an inner support unit (26) arranged therebetween, wherein: the inner support unit (26) supports at least one high-voltage electrical component that is different from the plurality of high-voltage energy storages (36); and / or the inner support unit (26) supports the high-voltage power distributor (40), the at least one DC-DC converter (44), the on-board charger (48), the heater (42) and / or the high-voltage interface (52); and / or the outer support units (26) support at least one low-voltage electrical component, preferably the steering pump (50), the cooling system (38) and / or the at least one low-voltage energy storage (46); and / or the inner support unit (26) supports at least one high-voltage electrical component, which differs from the plurality of high-voltage energy storages (36) and which is arranged in a vertical direction upwards at least partially protruding above the central support unit (26), preferably for protected arrangement between main longitudinal beams (14) of the vehicle frame (12).

12. The energy module (10) according to any one of the preceding claims, wherein: the crash structure (32) is formed, preferably formed from sheet metal and / or plastic, by a three-dimensional profile structure, preferably a trapezoidal profile structure, and / or by a metal foam.

13. The energy module (10) according to any one of the preceding claims, wherein: the support structure (22), preferably a base frame (24) of the support structure (22), comprises an underride protection element (39) on at least one outer side, preferably a front side and a rear side of the supporting structure (22), preferably in the form of an inclined underride protection plate arranged on a lower edge of the outer side.

14. A utility vehicle, preferably a lorry or bus, comprising an energy module (10) according to any one of the preceding claims, wherein the energy module (10) is attached from below to a vehicle frame (12), preferably a ladder frame, of the utility vehicle, preferably between a front axle (16) and a rear axle (18) of the utility vehicle.