Vehicle and method for retrofitting a vehicle

Abstract

The invention relates to a vehicle and a method for retrofitting a vehicle. According to a first aspect, the problem addressed is solved by a vehicle, wherein the vehicle belongs to the group of commercial vehicles, special vehicles and mobile working machines, for transporting people and / or goods, with a driver's cab and a fuel cell system, having a fuel cell, wherein the fuel cell has a substantially cuboidal outer contour with a length I, a width b and a height h, wherein the length I is greater than the width b, further having a plurality of auxiliary units, including an air compressor, a cooling system for the fuel cell and a cooling system for further auxiliary units and a voltage converter, wherein the vehicle has a ladder-type frame with two longitudinal members as a supporting chassis and wherein the fuel cell system is installed under the driver's cab at least partially between the two longitudinal members, wherein the width b of the fuel cell extends in the direction of the longitudinal members.

Description

[0001] VEHICLE AND METHOD FOR CONVERTING A VEHICLE

[0002] The invention relates to a vehicle and a method for converting a vehicle.

[0003] Currently, discussions about environmental protection and electromobility are omnipresent. Electric vehicles are emission-free during operation. Unlike combustion engines, they do not produce any direct emissions.

[0004] Various state-of-the-art solutions exist for making motor vehicles or vehicles fully electric or hybrid. To achieve this, the design of the motor vehicle or vehicle in question is often adapted to the drive type or planned that way from the outset. Thus, each time a new vehicle concept and a new vehicle are created.

[0005] When developing a truck, especially a tractor unit, using hydrogen as an energy source, one faces the choice of either using the stored energy directly in a combustion engine to convert it into kinetic energy, or generating electrical energy via a fuel cell, which can generate kinetic energy via an electric motor. Due to the higher efficiency and the reduced pollution, the use of a fuel cell, as described in the second alternative, is advantageous.

[0006] Today's series-ready fuel cells predominantly have a cuboid-shaped outer casing. In a truck, especially a tractor unit, the area below the driver's cab, where the diesel engine is located in a conventional truck, especially a tractor unit, is particularly suitable for the fuel cell due to its good weight distribution. Since the installation space for the installed diesel engine is usually not cuboid-shaped, this space cannot be optimally utilized with today's common fuel cells.

[0007] The object of the present invention is to provide an improvement or an alternative to the prior art.According to a first aspect, the stated object is achieved by a vehicle, wherein the vehicle belongs to the group of commercial vehicles, special-purpose vehicles and mobile work machines, for transporting persons and / or goods, having a driver's cab and a fuel cell system, comprising a fuel cell, wherein the fuel cell has a substantially cuboid-shaped outer contour with a length l, a width b and a height h, wherein the length l is greater than the width b, further comprising a plurality of auxiliary units, including an air compressor, a cooling system for the fuel cell and a cooling system for further auxiliary units and a voltage converter, wherein the vehicle has a ladder frame with two longitudinal members as a supporting chassis and wherein the fuel cell system is installed below the driver's cab at least partially between the two longitudinal members, wherein the width b of the fuel cell extends in the direction of the longitudinal members.

[0008] It should be expressly pointed out that, in the context of this patent application, indefinite articles and indefinite numerical expressions such as "one...", "two...", etc. are generally to be understood as "at least one...", "at least two...", etc., unless the context or the specific text of a particular passage indicates that only "exactly one...", "exactly two...", etc. are intended. Furthermore, all numerical expressions and information on process parameters and / or device parameters are to be understood in the technical sense, i.e., subject to the usual tolerances. Even the explicit specification of the restriction "at least" or "at least" or similar does not imply that the simple use of "one", i.e., without specifying "at least" or similar, means "exactly one."

[0009] In this case, a vehicle can be understood as a vehicle model that was originally designed for use with an internal combustion engine. In its original state, the vehicle either has a drive unit with an internal combustion engine or is at least designed for this purpose. In this case, a vehicle can also be understood as a vehicle in a variation of a vehicle series that is based on a basic type of vehicle that is manufactured in many different variations and that has a design space that was originally designed for use with an internal combustion engine. In its original state, the vehicle in a vehicle series does have a design space for use with an internal combustion engine, but in this state it does not necessarily have to have a drive unit with an internal combustion engine.

[0010] The original condition of a vehicle is understood here as the vehicle's delivery condition. This describes the condition in which a manufacturer intends to sell the vehicle. In its original condition, the vehicle usually has a drive unit with an internal combustion engine. However, it should also be recorded that the vehicle is delivered without an engine and the internal combustion engine is purchased separately and converted there, and / or an electric motor is purchased.

[0011] An internal combustion engine drive principle is understood to be a drive principle that features a drive unit with an internal combustion engine as the core engine. Typically, such a drive principle features a plurality of auxiliary units driven by a crankshaft.

[0012] A vehicle with an electrically powered drivetrain is understood to mean a drive principle that features a drive unit with at least one electrically powered motor. This drive unit is also referred to below as a "replacement unit" or "drive unit with an electric motor," although according to the invention it can contain one, two, three, four, or more motors.

[0013] Thus, the "conversion" can consist of removing a drive unit with an internal combustion engine from the vehicle, preferably only removing the core engine with a combustion principle from the vehicle; or of purchasing a drive unit with an internal combustion engine separately and removing the core engine with a combustion principle from the drive unit, with the remaining parts of the drive unit being operatively connected to the electric motor. Likewise, the installation space of the drive train can be understood as the installation space for the entire mechanical assembly, from the drive to the wheel bearings. In one variant, a vehicle according to the invention can have a drive provided by one or more e-axles, i.e., one or more rear axles with an included electric motor.

[0014] A fuel cell system is defined here as a system with at least one fuel cell and possibly auxiliary units. A fuel cell generates electrical energy from the energy sources hydrogen, low-molecular-weight alcohols (methanol, ethanol), or ammonia. Preferably, a fuel cell generates electrical energy that can be directly converted into motion by the electric drive of the backup unit. If the fuel cell generates more electrical energy than the electric drive of the backup unit can convert at that moment, the electrical energy can be temporarily stored in a traction battery.

[0015] In this case, a drive battery is understood to be an electrical storage device which primarily makes the electrical energy stored in it available to the backup unit.

[0016] Relative location terms such as "below" or "above" with reference to the vehicle or a vehicle part are to be interpreted as referring to a vehicle's use position. For example, stating that the fuel cell system is installed below the driver's cab means that the fuel cell is installed between the driver's cab and the ground or road on which the vehicle is parked or traveling.

[0017] The electric motor drive that can be used in the present invention can consist of an electric motor in the engine compartment of the vehicle, in which case the combustion core engine has been replaced as part of the "conversion", or it can consist of an electric motor on at least one axle, thus an e-axle, in which case at least the conventional axle has been replaced as part of the "conversion" and is replaced by an e-axle; whereby the modification by using an electric motor drive principle can take place not only in one place (i.e. engine compartment or axle), but also in two places, i.e. in the engine compartment and on the axle.This is to be understood in this way because, within the scope of the present invention, two different electric motor drive principles can be used: either the drive principle of a so-called BEV, i.e. a battery-electric vehicle, with an electric motor in the engine compartment, whereby the electric motor is used to convert electrical energy into mechanical energy and the mechanical energy uses the original drive train to transmit the mechanical energy, or a so-called FCEV, i.e. a fuel cell-electric vehicle, with a fuel cell in the engine compartment and with an e-axle for converting electrical energy into mechanical energy.

[0018] Ultimately, during the conversion, (at least) one component selected from the group of electric motor, battery, fuel cell can be installed in a space selected from the group of engine compartment for combustion engine, core engine space with combustion engine, transmission compartment, axle, in order to convert a vehicle into a BEV or FCEV.

[0019] Before installing the replacement unit, any existing drive unit with combustion engine can first be mechanically separated from the vehicle, so that the drive unit with combustion engine with the connected ancillary units is removed from the vehicle and separated at a number of interfaces.

[0020] According to the inventors' considerations, the at least one functionally connected auxiliary unit coupled to the existing drive unit can be a unit from the group consisting of a generator, hydraulic pump, power steering pump, water pump, air conditioning compressor, compressor for an air brake, compressor for engine charging, turbocharger, alternator, lubricant pump, cooling water pump, fuel pump, injection pump, metering pump, fan, compressed air generator, starter, auxiliary power unit, brake booster, hydrodynamic continuous brake, electrodynamic continuous brake, vacuum pump, and rudder system of a watercraft. Auxiliary units are driven either directly (via V-belts or gears) or indirectly (electrically or hydraulically) by the vehicle's drive engine. Due to their greater flexibility, the use of electrically operated auxiliary units is becoming more prevalent in automotive construction today, allowing for greater flexibility at the assembly site.In addition, an electrically powered auxiliary unit is independent of the vehicle's main drive, allowing it to remain operational even when the vehicle is stationary, for example, during stop-and-go operation. Electrically powered auxiliary units also contribute to energy savings, as the drive only runs when needed and doesn't have to be constantly driven by the V-belt.

[0021] Auxiliary units, such as the coolant pump, the compressor for the air conditioning system, the oil and water pumps and, in the passenger car sector, also the power steering pump, are coupled to the speed of the combustion engine with a fixed ratio.

[0022] However, in combustion engines, many of these components serve only to ensure the engine's functionality or exhaust gas purification. These components, such as lubricating oil and fuel pumps or the catalyst preheater, are no longer required in electric drivetrains and are therefore eliminated.

[0023] However, other functions must also be guaranteed in electric vehicles or are desired by the customer, which is why at least the following components are usually installed: steering assistance, braking assistance, lights, air conditioning / heating and battery cooling.

[0024] The problem with electric vehicles is that these units can no longer be driven mechanically like a combustion engine because the electric motor, and therefore the drive shaft, do not rotate when stationary. Many of the auxiliary drives would then be unavailable when stationary. Therefore, all components must be powered by the battery, which has a direct impact on their design. Many of the units were mechanically or hydraulically controlled due to their connection to the drive shaft and must be redesigned and configured for purely electric operation. For example, new concepts are required for steering assistance and braking systems. Thermal management in electric vehicles is also of great importance. In addition to heating and air conditioning, it is responsible for cooling the battery. Because the electric motor virtually produces no waste heat, these functions must also be provided purely electrically.This can be particularly problematic in winter, as the electrical heating of the vehicle and possibly the battery for starting can be very energy-intensive and thus has a direct impact on the range. Operating the auxiliary units can reduce the range by up to 20%, and in very low outside temperatures, even by up to 50%. One way to reduce this additional strain on the battery would be to use the times when the vehicle is connected to an external power grid for charging. If these charging processes are immediately followed by journeys, the energy for the auxiliary air conditioning and battery heating could be drawn from the grid instead of the battery.

[0025] All pump systems, such as air compressors, servo pumps, etc., must now be equipped with energy-optimized special electric motors to continue operating. This new requirement opens up enormous optimization opportunities for the units themselves. Since the combustion engine's speed is no longer forced, energy savings can be achieved through demand-based control, and weight reduction can be achieved by increasing the operating speed.

[0026] In the event that the vehicle has another drive unit with an internal combustion engine installed in the installation space for a drive unit with an internal combustion engine, the step of removing the drive unit with an internal combustion engine precedes the installation of the electric drive unit.

[0027] The conversion can also be carried out on vehicles which have the installation space for a drive unit with an internal combustion engine because they were designed for a drive unit with an internal combustion engine but were never equipped with one. For this example, there are some vehicle manufacturers who offer the option of purchasing their vehicles without a drive unit. By installing the fuel cell system below the driver's cab, at least partially between the two side members, the vehicle's center of gravity is low, which increases the vehicle's stability, particularly in critical driving situations. By installing the fuel cell system in the direction of the side members, with the width b of the fuel cell extending in the direction of the side members, it is in most cases possible to install a fuel cell system with several, for example two, fuel cells arranged one behind the other in the direction of travel of the vehicle, into the available installation space.This allows the power generation capacity of the fuel cell system to be increased. This makes it possible, for example, to install a fuel cell system in a vehicle that offers more power generation capacity than a fully loaded semi-trailer truck requires to maintain its maximum speed on a level stretch of road. The additional energy required, for example, for acceleration and / or driving uphill can then be provided at least partially by the higher power generation capacity of the fuel cell system and / or a traction battery. The traction battery can be recharged during downhill driving and / or by the power generation capacity not provided by the fuel cell system for maintaining speed on a level stretch of road.

[0028] In one embodiment of the vehicle according to the invention, the fuel cell protrudes beyond the longitudinal members in both directions of its height h. This allows for better utilization of the available installation space, allowing for the installation of a correspondingly powerful fuel cell system.

[0029] In a further embodiment, auxiliary components extend beyond at least one longitudinal member in the direction of the fuel cell's width b. This further utilizes the available installation space, allowing the installation of a correspondingly powerful fuel cell system.

[0030] In a further embodiment, the ancillary units protrude exclusively above the longitudinal members in the direction of the width b of the fuel cell, at least beyond one longitudinal member. This facilitates the installation of the fuel cell system from above. In Europe, the cab-over-engine (COE) design is widespread for trucks. This design allows more of the legally limited length of trucks to be used for the load. COEs also have a smaller turning circle than bonnet-type vehicles. In such COEs, the driver's cab is usually foldable, so that the drive unit can be installed, removed and serviced from above.

[0031] In a further embodiment, the fuel cell has a subframe on each of its two end faces in the direction of its length I, via which the fuel cell can be placed on the two longitudinal members. The subframe simplifies the installation of a fuel cell system in a truck.

[0032] In a further embodiment, the vehicle has a fuel cell system with at least two fuel cells. This allows for higher power generation capacity in the vehicle.

[0033] In a further embodiment, the vehicle has at least one front axle and at least one rear axle, with wheels attached to the axles, and the wheels of at least one rear axle are driven by an electric motor. Commercial vehicles, especially heavy-duty vehicles, have rear-wheel drive, as this improves traction compared to a front-wheel drive commercial vehicle. Heavy-duty vehicles typically have a permissible total weight of more than 3.51 tons, in particular more than 12 tons.

[0034] In another embodiment, the electric motor is designed as an axle motor. This design creates space for a larger fuel cell system and / or a larger drive battery, allowing the vehicle to generate and utilize more power accordingly. This is particularly advantageous for heavier vehicles, especially heavy-duty vehicles, and / or areas with numerous and / or steep gradients.

[0035] In another embodiment, the axle motor is integrated into at least one rear axle. This arrangement has a very compact design.

[0036] In an alternative embodiment, the axle motor is flange-mounted to at least one rear axle, whereby a drive torque can be generated via the axle motor, which can be transmitted to the at least one rear axle via a transmission. This allows the use of a standardized axle motor.

[0037] In addition, the drive torque can be adjusted via the transmission.

[0038] According to a further aspect of the invention, the object is achieved by a vehicle, wherein the vehicle belongs to the group of commercial vehicles, special-purpose vehicles and mobile work machines, for transporting persons and / or goods, in particular a commercial vehicle in the form of a truck, especially a truck of the cab-over type, with a driver's cab and a fuel cell system, comprising a fuel cell, wherein the fuel cell has a substantially cuboid-shaped outer contour with a length l, a width b and a height h, wherein the length l is greater than the width b, further comprising several auxiliary units, including an air compressor, a cooling system for the fuel cell and a cooling system for further auxiliary units and a voltage converter, wherein the vehicle has a ladder frame with two longitudinal members as a supporting chassis,The fuel cell system is installed below the driver's cab at least partially between the two longitudinal members, with three fluid guides arranged on one side of the fuel cell: a first fluid supply for cooling the fuel cell, a second fluid supply for cooling auxiliary components, and a fluid discharge away from the fuel cell. A fluid guide is understood here to be a device through which the fluid can flow. This can be, for example, a pipe and / or a hose suitable for the respective fluid, for example, water or air. The fluid guide can have one or more connections, branches, and / or valves.

[0039] This embodiment also increases the stability of the vehicle, particularly in critical driving situations, due to the low center of gravity. A fuel cell system with several, for example, two, fuel cells arranged one behind the other in the direction of travel of the vehicle can be installed in the available space, allowing the fuel cell system to generate the highest possible power. In a further embodiment, at least the two fluid supply lines are routed above the ladder frame along a longitudinal member. This facilitates the installation of the fuel cell system from above.

[0040] According to a second aspect of the invention, the stated object is achieved by a method for converting a vehicle from an ICE drive principle to an FCEV drive principle, wherein an internal combustion engine is removed from the vehicle, thereby creating an available installation space in addition to the already available installation space, and subsequently a fuel cell system is installed in the available installation space in the vehicle, whereby a vehicle according to the invention is produced.

[0041] It can be either a new vehicle or a used vehicle that has been converted according to the described method. Preferably, any superstructures on the vehicle and / or accessories can be operated in the same way as they would be in a vehicle of the same design with a combustion engine drive unit. It is preferred that external units that are operatively connected to the combustion engine drive unit in comparable vehicles can be made available in the same way by the replacement unit.

[0042] The embodiments described above can be used individually or combined with each other as desired.

[0043] The invention will be explained in more detail below using exemplary embodiments with reference to the drawings, in which

[0044] Fig. 1 Schematic diagram of a fuel cell installed between the longitudinal beams below the driver's cab of a commercial vehicle in a plan view from the front

[0045] Fig. 2 Schematic diagram of a fuel cell installed between the longitudinal members below the driver's cab of a commercial vehicle, viewed from the left side of the vehicle. Fig. 1 shows in principle how a fuel cell 10 with a width b and a height h is installed in a forward-control commercial vehicle according to the invention with a driver's cab 20, which has a ladder frame with two longitudinal members 21 as a supporting chassis. The commercial vehicle has a front axle 23, to which two front wheels 22 are attached, which rest on the ground 30. The front axle 23 is attached to the longitudinal members 21 (not shown). The fuel cell 10 is installed below the driver's cab 20, partially between the two longitudinal members 21.The fuel cell 10 projects beyond the longitudinal members 21 in both directions of its height h and has a subframe 12 on each of its two end faces in the direction of its length I, via which it is mounted on the two longitudinal members 21. In the illustrated embodiment, the fuel cell 10 is installed in front of the front axle 23 as viewed in the direction of travel. In other embodiments, the fuel cell 10 can also be installed above or behind the front axle 23 as viewed in the direction of travel. Furthermore, four fluid guides 11 are shown as examples. The fluid guides 11 can be, for example, cooling medium supplies and / or discharges. Cooling water, for example, can be used as the cooling medium. The fluid guides 11 are arranged above the longitudinal members 21.

[0046] Fig. 2 shows the embodiment of Fig. 1 in a view of the left side of the vehicle. This view shows the dimensions I of the fuel cell 10, with the length I of the fuel cell 10 being greater than its width b.

[0047] In the illustrated embodiment, only one fuel cell 10 is shown. However, viewed in the direction of travel, one or more additional fuel cells 10 may be arranged behind the illustrated fuel cell 10.

[0048] The described embodiments represent only examples of the present invention and should therefore not be understood as limiting. Alternative embodiments contemplated by those skilled in the art are equally encompassed within the scope of the present invention. List of reference symbols

[0049] 10 fuel cell

[0050] 11 Fluid guidance

[0051] 20 Driver's cab 21 Longitudinal member

[0052] 22 front wheel

[0053] 23 Front axle

[0054] 30 floor, street

Claims

Patent claims 1. A vehicle, wherein the vehicle belongs to the group of commercial vehicles, special-purpose vehicles, and mobile work machines, for transporting persons and / or goods, comprising a driver's cab (20) and a fuel cell system, comprising a fuel cell (10), wherein the fuel cell (10) has a substantially cuboid-shaped outer contour with a length l, a width b, and a height h, wherein the length l is greater than the width b, further comprising a plurality of auxiliary units, including an air compressor, a cooling system for the fuel cell (10), a cooling system for further auxiliary units, and a voltage converter, wherein the vehicle has a ladder frame with two longitudinal members (21) as a supporting chassis, characterized in that the fuel cell system is installed below the driver's cab (20), at least partially between the two longitudinal members (21).wherein the width b of the fuel cell (10) extends in the direction of the longitudinal beams (21).

2. Vehicle according to claim 1, characterized in that the fuel cell (10) projects beyond the longitudinal members (21) in both directions of its height h.

3. Vehicle according to claim 1 or 2, characterized in that the auxiliary units project in the direction of the width b of the fuel cell (10) at least beyond one longitudinal member (21).

4. Vehicle according to claim 3, characterized in that the auxiliary units project exclusively above the longitudinal members (21) in the direction of the width b of the fuel cell (10) at least beyond one longitudinal member (21).

5. Vehicle according to one of the preceding claims, characterized in that the fuel cell (10) has a subframe (12) on each of its two end faces in the direction of its length I, via which the fuel cell (10) can be placed on the two longitudinal beams (21).

6. Vehicle according to one of the preceding claims, characterized in that the vehicle has at least one fuel cell system with at least two fuel cells (10).

7. Vehicle according to one of the preceding claims, characterized in that the vehicle has at least one front axle (23) and at least one rear axle, wheels being attached to the axles, the wheels of at least one rear axle being drivable via an electric motor.

8. Vehicle according to claim 7, characterized in that the electric motor is designed as an axle motor.

9. Vehicle according to claim 8, characterized in that the axle motor is integrated in the at least one rear axle.

10. Vehicle according to claim 8, characterized in that the axle motor is flanged to at least one rear axle, wherein a drive torque can be generated via the axle motor and can be transmitted to the at least one rear axle via a transmission.

11. A vehicle, wherein the vehicle belongs to the group of commercial vehicles, special-purpose vehicles and mobile work machines, for the transport of persons and / or goods, in particular a commercial vehicle in the form of a truck, especially a truck of the cab-over type, with a driver's cab (20) and a fuel cell system, comprising a fuel cell (10), wherein the fuel cell (10) has a substantially cuboid-shaped outer contour with a length l, a width b and a height h, wherein the length l is greater than the width b, further comprising a plurality of auxiliary units, including an air compressor, a cooling system for the fuel cell (10) and a cooling system for further auxiliary units and a voltage converter, wherein the vehicle has a ladder frame with two longitudinal members (21) as a supporting chassis, in particular a vehicle according to one of the preceding claims, characterized in that the fuel cell system is installed below the driver's cab (20) at least partially between the two longitudinal members (21), wherein three fluid guides (11) are arranged on one side of the fuel cell (10), namely a first fluid supply (11) for cooling the fuel cell (10), a second fluid supply (11) for cooling auxiliary units and a fluid discharge (11) away from the fuel cell (10).

12. Vehicle according to claim 11, wherein at least the two fluid supplies (11) are guided above the ladder frame along a longitudinal member (21).

13. A method for converting a vehicle from an ICE drive principle to an FCEV drive principle, wherein an internal combustion engine is removed from the vehicle, thereby creating an available installation space in addition to the already available installation space, and then a fuel cell system is installed in the available installation space in the vehicle, wherein a vehicle is produced according to one of the preceding claims.

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