Utility vehicle having a modular battery case

Abstract

The invention relates to a utility vehicle, in particular a battery-driven trailer (20) for coupling to a tractor, comprising: a chassis (21) which is formed by longitudinal and cross-members (23, 24) and on the underside (22) of which at least one, in particular two or three trailer axles are arranged, at least one axle being equipped with an electric drive unit for driving and decelerating the utility vehicle; and at least one battery case (10) which is arranged on the underside (22) of the chassis (21) and which is used to receive exchangeable battery modules (50). According to the invention, a suspension device (30) is provided which detachably connects the battery case (10) to the chassis (21), the battery case (10) being mounted on the chassis (21) by means of the suspension device (30) in such a way that the battery case is mechanically decoupled from the chassis (21), and the battery case (10) being modular and having a modular cage structure (15) which is formed by at least one upper frame (11) for detachably fixing to the suspension device (30) and by at least one parallel lower frame (12) for receiving exchangeable battery modules (50) and for detachably fixing to the upper frame (11), in order to allow battery modules (50) to be quickly and safely exchanged in an upward direction or in a downward direction.

Description

[0001] July 23, 2025

[0002] 82685-0028-PWO - Ra / Oka

[0003] Applicant: Trailer Dynamics GmbH

[0004] Stitch 26

[0005] 52249 Eschweiler

[0006] Commercial vehicle with modular battery box

[0007] The invention relates to a commercial vehicle, in particular a battery-electrically powered trailer for coupling to a tractor unit, according to the preamble of claim 1 and a method for safely and quickly exchanging battery modules according to claim 21.

[0008] Trailers (also called semi-trailers, articulated trailers, or in English, semi-trailers) are generally used for transport and work purposes, for example in freight transport or agriculture. For a long time, they were considered unmotorized commercial vehicles and are usually attached to and towed by a kingpin on the fifth wheel coupling of a typically diesel-powered tractor unit.

[0009] Trailers typically feature a chassis constructed with crossbeams and longitudinal beams, or a ladder frame, and are usually multi-axle. Trailers and semi-trailers have two or three axles, respectively. 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 and transmission unit. This allows the trailer drive to support the tractor unit during acceleration and deceleration phases as needed, thereby improving the overall energy efficiency of the commercial vehicle. Due to the system's design, large and heavy high-voltage battery modules are necessary to power such a trailer.The high-voltage battery modules must be securely stored on the chassis of the trailer using a battery box.

[0010] In this context, particular challenges arise regarding installation space. Furthermore, the battery housing must meet increased safety requirements and withstand dynamic loads due to the high-voltage components. Moreover, the demands placed on the structural integrity of the battery box are high. The battery modules housed within the battery box must be effectively protected against environmental influences such as moisture and dust. Protecting the electrical components necessitates a relatively rigid structure. However, the trailer chassis has considerably more flexibility with regard to these requirements than the battery box.

[0011] Especially torsionally flexible chassis pose a major challenge for attaching the relatively rigid battery box.

[0012] To achieve the greatest possible range, especially with battery-electric commercial vehicles and trailers, it is inherently 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 the potentially lengthy charging periods. Furthermore, the high weight of the battery modules leads to a reduction in the payload of the vehicle or its combined vehicle.

[0013] For example, German patent DE 102022 123 162 B3 already proposes commercial vehicles with partially modular battery box or cage structures, but these are limited by various structural and functional disadvantages. The proposed solutions also suffer from a lack of modularity and flexibility, and in particular, problems with the maintenance and replacement of the battery modules. Often, therefore, a quick exchange of the battery modules, for example at a designated swapping station, has to be forgone, and very heavy battery modules must be carried that directly provide the entire energy capacity required for the route.

[0014] 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-electrically powered trailer, with an improved battery box.

[0015] The main features of the invention are specified in the characterizing part of claim 1. Embodiments are the subject of claims 2 to 21.

[0016] In a commercial vehicle, in particular a battery-electrically powered trailer for coupling to a tractor unit, comprising a chassis formed by longitudinal and transverse beams, on the underside 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 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 modularly designed and has a modular cage structure.which is formed by at least one upper frame for detachable fixing to the suspension device and at least one parallel lower frame for receiving replaceable battery modules and for detachable fixing to the upper frame, in order to enable a quick and safe replacement of battery modules from bottom to top or from top to bottom.

[0017] Due to the modular battery box according to the invention, which is attached to the chassis via a fully mechanically decoupled suspension device and supports easy replacement of battery modules via its modular cage structure, it offers a variety of technical advantages.

[0018] Mechanical decoupling effectively isolates vibrations and shocks that occur during driving from the battery box and the battery modules it contains. This not only leads to an increased lifespan for the battery modules, as mechanical stresses are minimized, but also to a

[0019] Improvement of the driving safety and driving stability of the entire commercial vehicle.

[0020] Mechanical decoupling from the chassis refers to a design measure in which the battery box is mounted to the chassis of a commercial vehicle, particularly 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 by using 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 dynamic loads generated by the vehicle's movement (e.g., due to uneven road surfaces, cornering, or braking), preferably in the longitudinal direction L, lateral direction Q, and vertical direction H, are not transmitted to the battery box. Through mechanical decoupling, dynamic loads generated during vehicle operation are effectively isolated.Insulation 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 facilitates the battery module replacement process.

[0021] Mechanical decoupling can preferably be achieved through a special mounting system in which the battery box is connected to the chassis only via silent blocks. These silent blocks are made of an elastic material that largely absorbs the forces and minimizes the transfer of kinetic energy to the battery box. As a result, 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 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 driving dynamic loads are effectively isolated, thereby protecting the battery box from mechanical stresses that the chassis exerts on it due to driving dynamics.

[0022] The modular cage structure of the battery box also allows for easy adaptation to different battery module sizes and ensures quick and safe replacement of the battery modules. This is particularly advantageous in applications where high vehicle availability is crucial, as downtime for charging or maintaining the batteries is minimized. Replacing the battery modules from top to bottom means removing a discharged battery vertically from top to bottom and inserting a charged battery from bottom to top. The modularity of the cage structure according to the invention and the simple and quick interchangeability of the battery modules housed within it advantageously offer a flexible and adaptable design in which the battery box structure is designed to be suitable for various battery capacities and types.The modular structure consists of individual components and can preferably be designed according to a building block system, allowing for easy assembly, replacement, or adaptation. This makes it possible to configure and adapt the structure for differently sized battery modules without significant effort. Overall, this design enables greater operational efficiency and reduces maintenance and operating costs in the long term.

[0023] The invention thus enables the use of a smaller battery capacity and therefore a lower battery weight. This significantly increases energy efficiency during ferry operation. Furthermore, the battery-electric vehicle can be equipped with the appropriate battery capacity for the specific route to be covered. A suitable infrastructure, such as charging / exchange stations, can further increase efficiency and support the invention.

[0024] The invention thus offers several advantages overall with regard to function, cost, quality, lifespan, deterioration, wear and tear, manufacturing and safety.

[0025] According to a preferred embodiment, the suspension device can comprise fixing profiles that can be detachably fixed to the longitudinal beams on both sides of the chassis frame. The fixing profiles can have flat, vertically oriented contact surfaces for resting against an inner profile of the longitudinal beams and two support arms each for resting on the surfaces of mounting rails. The fixing profiles, which are detachably fixed to the longitudinal beams of the chassis, ensure an extremely stable yet flexible attachment of the battery box to the chassis. The vertical orientation 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 distributing the weight of the battery box evenly across the mounting rails.This design ensures secure mounting while allowing for easy release when battery modules need to be replaced or maintenance is required. This increases the system's flexibility and ease of maintenance, which in turn reduces vehicle downtime.

[0026] Preferably, the support arms of the mounting profiles of the suspension device can extend laterally, and these support arms can be L-shaped. The L-shaped support arms, extending laterally, 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, minimizing deformation or movement during driving. This not only increases the safety of the battery box and the battery modules it contains, but also improves the driving dynamics of the commercial vehicle. The even load distribution and robust mounting ensure that the battery box remains securely in position even under strong vibrations or impacts, further increasing the operational reliability and service life of the system.

[0027] According to a preferred embodiment, the suspension device can comprise at least two mounting rails arranged parallel to the longitudinal beams on both sides of the chassis frame. These mounting rails can be designed to engage with fixing profiles of the suspension device. The mounting rails, arranged parallel to the chassis longitudinal beams, provide a solid and flexible base for attaching the suspension device and thus the entire battery box. These rails allow for easy adaptation of the suspension device to different vehicle models, significantly expanding the application possibilities of the modular battery box. The mounting rails also offer increased flexibility in the arrangement and alignment of the fixing profiles, simplifying and accelerating the installation process.This modularity helps to ensure that the battery box can be easily installed on different types of vehicles and quickly removed if necessary, further improving operational efficiency and ease of maintenance.

[0028] Preferably, the suspension device can comprise at least two mounting rails on each side of the chassis frame, aligned parallel to the longitudinal beams and featuring fixing elements for detachably connecting the mounting rails to the upper frame of the modular cage structure. Two longitudinally arranged mounting rails can have a longitudinal extent approximately corresponding to that of a longitudinally arranged mounting rail. The mounting rails with fixing elements, aligned parallel to the longitudinal beams, provide a reliable and flexible attachment of the upper frame of the modular cage structure to the chassis. This design allows for precise adaptation of the battery box to different battery module sizes and capacities and ensures stable mounting and fixing of the battery modules.The ability to flexibly position the mounting rails longitudinally allows the battery box to be optimally adapted to specific requirements, thus increasing the system's versatility and flexibility. Furthermore, this design facilitates the replacement and maintenance of the battery modules, as the battery box is securely and stably, yet easily detachable, attached to the chassis.

[0029] According to another preferred embodiment, the mounting rails and the receiving rails may have U-shaped profiles, with the receiving rails being arranged beneath the mounting rails and simultaneously side by side in the longitudinal direction. The U-shaped profiles of the mounting rails and receiving rails offer the advantage of increased structural stability while simultaneously 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, simplifying the installation process and increasing safety.Furthermore, the arrangement of the mounting rails below the mounting rails and their parallel alignment in the longitudinal direction enables efficient use of space, which further improves the flexibility of the system and allows for easy adaptation to different vehicle configurations.

[0030] Preferably, the suspension device can include elastic and vibration-damping silent bearings for adjusting the mechanical decoupling of the battery box. These silent bearings can be arranged on both sides of the chassis frame and designed as silent blocks to isolate vibrations and shocks while simultaneously facilitating the replacement of the battery modules. The use of elastic and vibration-damping silent bearings for the mechanical decoupling of the battery box from the chassis offers numerous advantages. These silent bearings effectively isolate the battery box from vibrations and shocks acting on the chassis during travel. This protects the sensitive battery modules from mechanical stress, extending their service life and increasing their operational reliability.Furthermore, the silent bearings facilitate the replacement of the battery modules, as they allow movement in multiple axes, thus ensuring flexible handling of the battery box. This leads to reduced maintenance times and increases the vehicle's efficiency in daily operation.

[0031] Preferably, the silent blocks for achieving complete mechanical decoupling of the battery box can dampen and isolate dynamic loads in the longitudinal, lateral, and vertical directions of the trailer. The silent blocks can be designed and arranged to stabilize the battery box in its position while simultaneously allowing mechanical movement along multiple axes to fully isolate dynamic loads. The ability of the silent blocks to dampen and isolate dynamic loads in the longitudinal, lateral, and vertical directions significantly improves the stability and safety of the battery box during travel. This feature ensures that the battery box remains securely and stably in position even under severe 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. Furthermore, the complete isolation of dynamic loads extends the service life of the battery box and the battery modules it contains, thus increasing the long-term reliability and efficiency of the system.

[0032] In 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 detachably and force-fitted to the mounting and receiving rails via fasteners. The silent bearings can have base plates on their undersides that bear against and 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 detachable. 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 silent blocks provide a stable contact surface, ensuring even load distribution and increasing the system's mechanical stability. These features not only facilitate the installation and removal of the battery box but also contribute to reducing wear and maintenance costs, further improving the vehicle's operating efficiency and simplifying the battery module replacement process.

[0033] Preferably, the modular cage structure of the battery box can be provided with additional reinforcing elements to increase its load-bearing capacity under high dynamic loads. These additional reinforcing elements can be formed by transversely projecting cross members, which may have recesses for stiffening and weight reduction. The additional reinforcing 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 reinforcing elements, formed by transversely projecting cross members, ensure that the battery box remains stable even under extreme operating conditions and that the battery modules contained within are reliably protected.The cutouts in the cross members serve to reduce weight without compromising structural integrity, thus increasing the vehicle's efficiency by reducing its overall weight. These features contribute to extending the battery box's service life and improving vehicle safety.

[0034] 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 oriented corner and cross members and longitudinally arranged lateral cross members, wherein the lateral cross members simultaneously 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 cross members to form the frame of the modular cage structure offers an optimal combination of structural strength and flexibility. This design allows for precise adaptation of the battery box to different battery module sizes and capacities and ensures stable and secure mounting of the battery modules.The lateral longitudinal crossmembers also function as side-impact protection, significantly increasing vehicle safety in the event of a side impact. This modular design allows for flexible adaptation of the cage structure to different operational requirements, increasing the system's versatility and reducing production costs, as the same basic structure can be used for various vehicle models. Furthermore, the modular cage structure of the battery box can preferably be designed to be adjustable in both the vertical and longitudinal directions to configure the mounting structure for battery modules of varying sizes. The modular cage structure can be designed to be mirror-symmetrical about a central longitudinal axis of the chassis, allowing for identical structures on both sides of the chassis frame to accommodate interchangeable battery modules.The adaptability of the modular cage structure in both vertical and longitudinal directions allows for flexible configuration of the mounting structure for battery modules of varying sizes, significantly increasing the system's versatility. This flexibility ensures that the battery box can be adapted to different battery module sizes, arrangements, and capacities without requiring extensive modifications to the basic structure. The mirror-symmetrical design of the cage structure with respect to a central longitudinal axis of the chassis allows for identical battery module mounting structures on both sides of the chassis frame. This increases efficiency in vehicle assembly and maintenance and reduces production costs through component standardization.

[0035] Preferably, the modular cage structure of the battery box can incorporate an integrated temperature monitoring and cooling system for the battery modules to ensure optimal operating temperature. This modular cage structure can be equipped with standardized interfaces to enable compatibility with various battery module types. The integrated temperature monitoring and cooling system within the modular cage structure ensures that the battery modules always operate under optimal temperature conditions, thereby increasing their efficiency and lifespan. Continuous monitoring of the operating temperature protects the batteries from overheating, reducing the risk of failure or damage.Furthermore, the use of standardized interfaces enables the easy integration of different battery module types, increasing the system's flexibility and ensuring compatibility with future battery technologies. This contributes to the vehicle's future-proofing and enhances its adaptability to changing technical requirements.

[0036] According to a preferred embodiment, the modular cage structure of the battery box can comprise several interchangeable battery modules stacked vertically. These modules are contained and securely held within the modular cage structure, which can be designed to provide accessibility and a working space for robot arms or corresponding tools used to replace the battery modules. The ability to stack multiple battery modules vertically maximizes the vehicle's energy density, resulting in increased range and efficiency. This stacking arrangement allows for optimal use of the available space within 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 reduced maintenance costs.

[0037] Preferably, the modular cage structure and the battery modules can have separable connections for high-voltage lines, coolant lines, and control lines, enabling the quick disconnection and connection of the replaceable battery modules. The upper and lower frames of the modular cage structure can have separable interfaces with fasteners for detachable connection and complementary receiving elements, which can be screw connections, quick-release couplings, locking elements, terminals, or plug connectors, to allow the battery box to be positioned and aligned for a quick and safe replacement process. The use of separable connections for high-voltage lines, coolant lines, and control lines enables quick and safe disconnection and connection of the battery modules, significantly speeding up the replacement process.These separable interfaces ensure that the electrical and mechanical connections can be easily and reliably disconnected and reconnected when replacing the 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 operational efficiency.

[0038] 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 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 a vertical direction. The guide elements for the battery modules can be designed such that they allow automatic self-correction of the battery modules during the replacement process, even in the case 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 feature minimizes the risk of misalignment that could lead to damage to the battery modules or the battery box.Automatic self-correction of positioning minimizes human error in the replacement process, increasing the system's reliability and safety. This precise alignment also contributes to a fast and efficient replacement process, reducing vehicle downtime and lowering operating costs.

[0039] Preferably, the modular cage structure of the at least one battery box can be equipped with an additional protection system that protects cyclists and pedestrians from being run over, in particular by being designed in accordance with the requirements of ECE Regulation 73, wherein the battery box can include a front and a rear attachment structure to improve aerodynamics and to accommodate additional battery ancillary components. This additional protection system, which protects cyclists and pedestrians from being run over, significantly increases the vehicle's road safety. This safety device, designed in particular in accordance with the requirements of ECE Regulation 73, not only protects other road users but also contributes to the vehicle's compliance with applicable safety regulations.The front and rear aerodynamic structures reduce drag, which lowers energy consumption and increases the vehicle's range. At the same time, these structures provide space for battery auxiliary components, further increasing the system's flexibility and improving overall system efficiency.

[0040] 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 be made of a lightweight metal material to optimize weight while still providing sufficient shielding, and the protective cladding of the battery box can be sealed with a weatherproof adhesive sealant at all cut and connection points of the modular cage structure. The additional lightweight metal protective cladding provides effective protection of the battery modules against 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 cover's weight, contributing to a reduction in the vehicle's overall weight and increasing energy efficiency. Weatherproof sealing of the cover with an adhesive sealant at all joints and connections ensures that the battery modules are permanently protected from moisture ingress, further extending the system's lifespan.

[0041] Preferably, the battery module replacement process can be performed manually using tools or fully automatically using a specially designed robotic device. The option of performing the battery module replacement either manually or fully automatically offers a high degree of flexibility in maintenance and allows the system to be adapted to various operational requirements. Manual replacement allows the process to be carried out with 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, thus maximizing the vehicle's uptime.

[0042] According to a further preferred embodiment, the trailer chassis can have two spaced-apart battery boxes containing replaceable battery modules, each 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 to the longitudinal members of the chassis. The arrangement of two spaced-apart battery boxes on the trailer chassis enables a uniform weight distribution, which improves the vehicle's driving stability and reduces the risk of tipping or instability.The use of mounting devices with multiple fixing profiles and silent bearings ensures secure and stable attachment of the battery boxes, further increasing the system's safety and reliability. This design allows for quick removal and replacement of the battery boxes when necessary, simplifying maintenance and increasing the vehicle's operational 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.

[0043] In a preferred embodiment, the lower frame of the modular cage structure can be equipped with conical connecting pins that 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 ensure that the battery modules can be positioned precisely during the swapping process. Furthermore, the conical connecting pin or the conical quick-connect fitting offers the advantage that minor misalignments of the vehicle within the swapping station during the swapping process can be compensated for by the tapered pins.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 incorporated into the design to enable this automatic correction. This contributes to making the battery module and / or cage structure replacement process more efficient and reliable by compensating for minor positioning deviations of the vehicle and thus ensuring precise locking of the battery modules.

[0044] According to a further preferred embodiment of the invention, the battery modules can be secured by special locking elements, in particular T-shaped locking elements, which can be released or locked either manually or by robot. The corresponding locking points are provided by the modular cage structure. The frames of the modular cage structure of the modular battery box can preferably be arranged symmetrically, such that structural segment chambers are created into which the battery modules can be inserted and removed from below using suitable tools. These modules are securely locked or released. The modular cage structure can preferably be provided with corresponding special recesses to accommodate the lower longitudinal frame members in the installation space-related support structure, thereby ensuring maximum ground clearance of the vehicle.

[0045] The distribution of two modular battery boxes, each containing four separately mounted battery modules, can preferably be designed such that the battery weights along the vehicle's axles provide balance, which can advantageously reduce the fifth-wheel load when empty. This balancing follows the principle of the classic lever and helps to reduce the load on the fifth wheel of the tractor unit. This positively influences the payload capacity of the vehicle or trailer, as the vehicle is better balanced overall and can carry a higher load without excessively stressing the axles.

[0046] Furthermore, preferably the modular cage structure can be adaptively designed in such a way that it can adapt to the different requirements and installation positions in different vehicle categories, especially in vehicle category O.

[0047] Preferably, the modular cage structure of the battery box can be designed to securely hold the battery modules while simultaneously allowing for quick and efficient replacement of these modules when needed. With a full complement of four battery modules, a usable battery capacity of approximately 712 kWh is preferably achieved, with a nominal capacity of 890 kWh.

[0048] Protection against moisture and dirt can preferably also 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 simultaneously ensuring the reliability of individual components.

[0049] 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 need to be aerodynamically optimized, and the protection of cyclists and pedestrians could be implemented as a supplementary add-on solution extending beyond the boundaries of the battery box structure. Furthermore, according to this design, it is preferable that the trailer chassis be designed with sufficient torsional rigidity.

[0050] According to an alternative preferred embodiment, the modular cage structure can be configured 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, into a pit). This alternative removal method could offer significant spatial advantages in certain scenarios, even if it does not always appear to be the most efficient solution at first glance. A swapping station is a specially equipped facility designed for the quick and efficient exchange of battery modules in electrically powered vehicles, especially commercial vehicles such as battery-electric trailers.At a swapping station, discharged battery modules are automatically or manually removed and replaced with fully charged modules without the vehicle being out of service for an extended period. This allows for a quick resumption of ferry operations and reduces downtime compared to conventional battery charging.

[0051] According to a further aspect, the invention relates to a method for the rapid and safe exchange of high-voltage battery modules in a commercial vehicle, in particular a battery-electric trailer, with a modular battery box, comprising the steps of: positioning the commercial vehicle over an exchange device; disconnecting separable connections for high-voltage lines, coolant lines, and control lines while the battery modules are safely detached 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; and automatic self-correction and locking of the battery modules by the guide elements and guide rails.Reconnecting the separable 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 ferry operation.

[0052] The procedure for the quick and safe replacement of high-voltage battery modules advantageously minimizes vehicle downtime while maximizing operating time. The structured sequence of steps, from positioning the vehicle and disconnecting the connections to safely removing the battery modules, reinstalling them, and performing a final inspection, ensures a precise and reliable replacement process. The automatic self-correction and locking of the battery modules by the guide elements and rails reduces the risk of misalignment and damage, thus increasing the system's safety and efficiency. Overall, this procedure helps to lower maintenance costs, maximize operating time, and improve the vehicle's reliability in daily use.

[0053] In a preferred embodiment, it is conceivable that an autonomous vehicle drives under the battery box, supports it, and, after disconnecting the connections to the trailer, transports the battery module to the charging station. In reverse order, this vehicle could assist with reinstalling the fully charged battery segment, which would make the process even more efficient and faster.

[0054] 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. The drawings show:

[0055] Fig. 1. a schematic perspective view of a trailer according to the invention with two battery boxes;

[0056] Fig. 2 shows a schematic assembly / exploded view of a modular cage structure of a battery box from Fig. 1, with integrated battery modules;

[0057] Fig. 3 shows a schematic detail view of the fastening of an upper frame of the modular cage structure with mounting rails;

[0058] Fig. 4 shows a schematic detail view of a suspension device of the trailer according to the invention with a modular battery box; Fig. 5 shows a schematic detail view of a fastening of mounting rails to a chassis of the trailer according to the invention.

[0059] The commercial vehicle generally designated as 20 in Fig. 1 is in particular a battery-electrically driven trailer 20 (not shown) for coupling to a tractor unit and comprises a chassis 21 formed by longitudinal and transverse beams 23, 24, which is illuminated in perspective in Fig. 1.

[0060] 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.

[0061] 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 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 beams 23 to each other.

[0062] The battery box 10 is modular in design and has a modular cage structure 15, which is formed by at least one upper frame 11 for detachable fixing with the suspension device 30 and at least one parallel lower frame 12 for receiving replaceable battery modules 50 and for detachable fixing with the upper frame 11, in order to enable a quick and safe replacement of battery modules 50 from bottom to top in the vertical direction H.

[0063] As can be seen from Fig. 2 and especially from Figs. 4 and 5, the suspension device 30 can comprise fixing profiles 33 which can be detachably fixed to the longitudinal beams 23 on both sides of the chassis 21 (see Fig. 1, fixed position). 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 resting on the surfaces of mounting rails 31. It can also be seen that the support arms 33" of the fixing profiles 33 of the suspension device 30 extend in the transverse direction Q, and the support arms 33" of the fixing profiles 33 can be L-shaped.

[0064] As can be seen further 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 beams 23 on both sides of the frame of the chassis 21, wherein the mounting rails 31 can be designed to be placed against the fixing profiles 33 of the suspension device 30.

[0065] The suspension device 30 can further comprise at least two receiving rails 32 on each side of the frame of the chassis 21, which are aligned parallel to the longitudinal beams 23 and can have fixing elements 37 for detachably connecting the receiving rails 32 to the upper frame 11 of the modular cage structure 15, wherein two receiving rails 32 arranged side by side in the longitudinal direction L can have a longitudinal extent that corresponds approximately to the longitudinal extent of a mounting rail 31 arranged in the longitudinal direction L (see in particular Fig. 2 and 4).

[0066] Figures 2 to 4 show that the mounting rails 31 and the receiving rails 32 can have U-shaped profiles, with the receiving rails 32 being arranged side by side under the mounting rails 31 and simultaneously in the longitudinal direction L. This facilitates the arrangement and enables precise assembly of the modular cage structure 15 of the battery box 10.

[0067] Fig. 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, wherein the reinforcement elements 19 are formed by transverse cross members projecting in the transverse direction Q, which may have recesses for stiffening and weight reduction. Furthermore, Fig. 2 shows that the upper and / or the lower frame 11, 12 of the modular cage structure 15 of the battery box 10 may be formed by corner and transverse cross members 16 oriented in the transverse direction Q and by lateral longitudinal cross members 18 arranged in the longitudinal direction L, wherein the lateral longitudinal cross members 18 simultaneously function as side impact protection and the modular cage structure 15 of the battery box 10 may be designed to be adaptable in order to accommodate battery modules 50 of different sizes.

[0068] Furthermore, Fig. 2 shows that the modular cage structure 15 of the battery box 10 can be adapted 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 in a mirror-symmetrical manner to a central longitudinal axis of the chassis 21, so that identical structures for receiving interchangeable battery modules 50 can be created on both sides of the chassis 21.

[0069] 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 sides of the frame of the chassis 21 and can be designed as silent blocks to isolate vibrations and shocks and at the same time facilitate the replacement of the battery modules 50.

[0070] Furthermore, as can be seen in Fig. 4, 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 adjusting the complete mechanical decoupling of the battery box 10, wherein the silent bearings 35 can be designed and arranged in such a way 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.

[0071] As further shown in Fig. 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 detachably fixed to the mounting and receiving rails 31, 32 by means of fastening elements 13'. The silent bearings 35 can have base plates 35' on their undersides, which are supported and rest on the surfaces of the receiving rails 32. Figure 5 illustrates the fastening option of the fixing profiles 33 to inner profiles 23' of the longitudinal beams 23 by means of fastening elements 13' or screw connections.

[0072] The modular cage structure 15 of the battery box 10 can incorporate an integrated device for temperature monitoring and cooling of the battery modules 50 to ensure optimal operating temperature. The modular cage structure 15 of the battery box 10 can be equipped with standardized interfaces that enable compatibility with various battery module types.

[0073] As shown in Figures 1 to 5, the modular cage structure 15 of the battery box 10 can comprise several interchangeable battery modules 50 stacked in the vertical direction H, which are received and securely held in the modular cage structure 15, the modular cage structure 15 being designed to ensure accessibility or a space for action for robot arms or corresponding tools used for changing the battery modules 50.

[0074] Furthermore, the modular cage structure 15 and the battery modules 50 can have separable connections for high-voltage lines, coolant lines, and control lines, enabling the quick disconnection 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 fasteners 13 for detachable connection and complementary receiving elements, which can be formed by screw connections, quick-release couplings, locking elements, connecting pins, or plug connections, to allow the battery box 10 to be positioned and aligned accordingly for a quick and safe replacement process.

[0075] As further illustrated in Figures 2, 3, 4 and 5, the modular cage structure 15 of the battery box 10 can be equipped with additional guide elements and guide rails that 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 in such a way that they can enable automatic self-correction of the battery modules 50 during the replacement process, even in the case of minimal deviations in positioning.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 run over, in particular by being designed in accordance with the requirements of Directive ECE-R73, wherein the battery box 10 can include a front and a rear attachment structure to improve aerodynamics and to accommodate additional battery ancillary units.

[0076] 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 simultaneously provides electromagnetic shielding (see in particular Fig. 2). The protective covering 51 of the battery box 10 can comprise a lightweight metal material to optimize weight while providing sufficient shielding and can be sealed with a weather-resistant adhesive sealant at all cut and connection points of the modular cage structure 15.

[0077] Furthermore, the replacement process of the battery modules 50 can be carried out manually using tools or fully automatically using a specially designed robot device for replacing the battery modules 50.

[0078] Finally, Figure 1 shows that the chassis 21 of the trailer 20 can have two spaced-apart battery boxes 10 with interchangeable battery modules 50 housed within them, each mounted on both sides of the chassis 21 via suspension devices 30, wherein the suspension devices 30 of the two battery boxes 10 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 beams 23 of the chassis 21.

[0079] Based on the figures and configurations shown, a method for the rapid and safe exchange of high-voltage battery modules 50 in a commercial vehicle, in particular a battery-electric trailer 20, with a modular battery box 10, comprises the following steps: positioning the commercial vehicle over an exchange device; disconnecting 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 separable 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 ferry operation.

[0080] The invention is not limited to one of the embodiments described above, but can be modified in many ways.

[0081] The scope of application 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 especially relevant for applications where high flexibility and efficiency in energy supply and use are required, as is the case with heavy trucks used for long-distance transport and freight haulage.

[0082] 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 demands and particular logistical challenges of heavy-duty transport. Electric trailers and semi-trailers designed for transporting goods over long distances particularly benefit from the ability to quickly and efficiently exchange battery modules, thereby minimizing downtime and maximizing operating time.

[0083] Furthermore, the invention can also be used in other areas of heavy-duty transport, such as construction and agricultural vehicles, which have similar requirements for energy supply and flexibility. Thanks to the adaptability of the modular battery infrastructure, the invention is suitable for a wide variety of application scenarios in which electric drive systems are playing an increasingly important role. With the ongoing electrification of road freight transport and the rising demands for sustainability and efficiency, this invention offers a forward-looking solution that can make the operation of heavy commercial vehicles more efficient and environmentally friendly. It helps to overcome the challenges in terms of range, charging times, and payload capacity associated with the introduction of electric drive systems in these vehicle categories.

[0084] All features and advantages arising from the claims, the description and the drawing, including design details, spatial arrangements and process steps, can be essential to the invention both individually and in various combinations.

[0085] Reference numeral list

[0086] L Vehicle longitudinal direction

[0087] Q Vehicle transverse direction

[0088] H Vehicle lifting direction

[0089] 10 battery boxes

[0090] 11 upper frame

[0091] 12 lower frame

[0092] 12 crossbeams

[0093] 13 fastening elements (connecting pins, plug connectors)

[0094] 13' Fastening elements (screw connections, screw-nut)

[0095] 14 exceptions

[0096] 15 modular cage structure

[0097] 16 corner and crossbeams

[0098] 17 Fixing element

[0099] 18 Longitudinal crossmember (side impact protection)

[0100] 19 Reinforcement element (crossbeams)

[0101] 20 trailers (commercial vehicle)

[0102] 21 chassis

[0103] 22 Underside (chassis)

[0104] 23 longitudinal beams (chassis)

[0105] 23' Inner profile longitudinal beam

[0106] 24 cross members (chassis)

[0107] 25 cross braces (chassis)

[0108] 30 Suspension device

[0109] 31 Mounting rail

[0110] 32 Mounting rail

[0111] 33 fixing profiles

[0112] 33' Plant area (plan)

[0113] 33" support arms (L-shaped)

[0114] 35 Silent bearings (silent blocks)

[0115] 35' Base plate (silent bearing)

[0116] 37 Fixing element

[0117] 50 replaceable battery modules (HV traction battery modules)

[0118] 51 Protective cladding (sheet metal cladding)

Claims

Patent claims 1. Commercial vehicle, in particular a battery-electrically powered trailer (20) for coupling to a tractor unit, 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) arranged on the underside (22) of the chassis (21) and serving to accommodate replaceable battery modules (50), characterized in that 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 modular in design and has a modular cage structure (15) formed by at least one upper frame (11) for detachable fixing to the suspension device (30) and at least one parallel lower frame (12) for accommodating replaceable battery modules (50) and for detachable fixing to the upper frame (11) in order to enable quick and safe replacement of battery modules (50) from bottom to top or from top to bottom to allow downwards.

2. Commercial vehicle according to claim 1, characterized in that the suspension device (30) comprises fixing profiles (33) which are detachably fixed to the longitudinal beams (23) on both sides of the frame of the chassis (21), wherein the fixing profiles (33) have flat contact surfaces (33') oriented in the vertical direction (H) for contacting an inner profile (23') of the longitudinal beams (23) and each have two support arms (33") for resting on surfaces of mounting rails (31).

3. Commercial vehicle according to claim 2, characterized in 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.

4. Commercial vehicle according to one of the preceding claims, characterized in that the suspension device (30) comprises at least two mounting rails (31) arranged parallel to the longitudinal beams (23) on both frame sides of the chassis (21), wherein the mounting rails (31) are designed to be placed against fixing profiles (33) of the suspension device (30).

5. Commercial vehicle according to one of the preceding claims, characterized in that the suspension device (30) on both frame sides of the chassis (21) comprises at least two receiving rails (32) which are aligned parallel to the longitudinal members (23) and have fixing elements (37) for detachably connecting the receiving rails (32) to the upper frame (11) of the modular cage structure (15), wherein two receiving rails (32) arranged side by side in the longitudinal direction (L) have a longitudinal extent which corresponds approximately to the longitudinal extent of a mounting rail (31) arranged in the longitudinal direction (L).

6. Commercial vehicle according to claims 4 and 5, characterized in that the mounting rails (31) and the receiving rails (32) have U-shaped profiles, wherein the receiving rails (32) are arranged next to each other under the mounting rails (31) and simultaneously in the longitudinal direction (L).

7. Commercial vehicle according to one of the preceding claims, characterized in that the suspension device (30) has elastic and vibration-damping silent bearings (35) for adjusting the mechanical decoupling of the battery box (10), wherein the silent bearings (35) are arranged on both sides of the frame of the chassis (21) and are designed as silent blocks to isolate vibrations and shocks and at the same time facilitate the replacement of the battery modules (50).

8. Commercial vehicle according to claim 7, characterized in that the silent bearings (35) for adjusting 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.

9. Commercial vehicle according to claims 4, 5 and 7 characterized in 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 force-fitted 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).

10. Commercial vehicle according to one of the preceding claims, characterized in that the modular cage structure (15) of the battery box (10) is provided with additional reinforcing elements (19) to increase the load-bearing capacity under high dynamic loads, wherein the additional reinforcing elements (19) are formed by transverse cross members projecting in the transverse direction (Q) which have recesses for stiffening and weight reduction.

11. Commercial vehicle according to one of the preceding claims, characterized in that the upper and / or the lower frame (11, 12) of the modular cage structure (15) of the battery box (10) are formed by corner and transverse cross members (16) oriented in the transverse direction (Q) and by lateral longitudinal cross members (18) arranged in the longitudinal direction (L), wherein the lateral longitudinal cross members (18) simultaneously serve as side impact protection and the modular cage structure (15) of the battery box (10) is designed to be adaptable in order to accommodate battery modules (50) of different sizes and to be able to use different battery capacities.

12. Commercial vehicle according to one of the preceding claims, characterized in 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 in a mirror-symmetrical manner to a central longitudinal axis of the chassis (21), so that identical structures for receiving interchangeable battery modules (50) are created on both sides of the chassis (21).

13. Commercial vehicle according to one of the preceding claims, characterized in that the modular cage structure (15) of the battery box (10) has an integrated device for temperature monitoring and cooling of the battery modules (50) to ensure the optimal operating temperature, wherein the modular cage structure (15) of the battery box (10) is equipped with standardized interfaces that enable compatibility with different battery module types.

14. Commercial vehicle according to one of the preceding claims, characterized in that the modular cage structure (15) of the battery box (10) comprises several interchangeable 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) is designed to ensure accessibility or a space for action for robot arms or corresponding tools used for changing the battery modules (50).

15. Commercial vehicle according to one of the preceding claims, characterized in 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 quick disconnection 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 formed by screw connections or quick couplings or locking elements or connecting pins or plug connections, in order to provide the possibility of positioning and aligning the battery box (10) accordingly for a quick and safe replacement process.

16. Commercial vehicle according to one of the preceding claims, characterized in that the modular cage structure (15) of the battery box (10) is equipped with additional guide elements and guide rails that 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 positioning.

17. Commercial vehicle according to one of the preceding claims, characterized in that the modular cage structure (15) of the at least one battery box (10) is provided with an additional protection system that protects cyclists and pedestrians from being run over, in particular 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 to improve aerodynamics and to accommodate additional battery ancillary components.

18. Commercial vehicle according to one of the preceding claims, characterized in that the modular cage structure (15) of the battery box (10) has 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 provides electromagnetic shielding, wherein the protective covering (51) of the battery box (10) comprises a light metal material to optimize the weight while providing sufficient shielding, and wherein the protective covering (51) of the battery box (10) is sealed with a weather-resistant adhesive sealant at all cut and connection points of the modular cage structure (15).

19. Commercial vehicle according to one of the preceding claims, characterized in that the replacement process of the battery modules (50) is carried out manually by the use of tools or fully automatically by the use of a specially provided robot device for replacing the battery modules (50).

20. Commercial vehicle according to one of the preceding claims, characterized in that the chassis (21) of the trailer (20) has two spaced-apart battery boxes (10) with replaceable battery modules (50) housed therein, each of which is mounted on both sides of the chassis (21) via suspension devices (30), wherein the suspension devices (30) of the two battery boxes (10) on each side of the chassis (21) provide at least three fixing profiles (33) and at least four silent bearings (35) for mounting the battery boxes (10) on the longitudinal beams (23) of the chassis (21).

1. Method for the rapid 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) according to one of the preceding claims, comprising the steps: a) positioning the commercial vehicle over a replacement device, b) disconnecting 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;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 ferry operation.

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