Abstract
A modular system for a vehicle. The modular system includes a plurality of energy source modules configured to be connected to or included in a propulsion system of a vehicle, each one of the energy source modules having a rectangular cross-section. The modular system also includes a support structure operatively connectable to a chassis of the vehicle, the support structure defining a space for receiving said energy source modules. At least one of the energy source modules is a pressurized vessel containing a gas. The invention also relates to a vehicle and to an installation method.
Claims
1. A modular system for a vehicle, comprising: a plurality of energy source modules configured to be connected to or included in a propulsion system of a vehicle, each one of the energy source modules having a rectangular cross-section, and a support structure operatively connectable to a chassis of the vehicle, the support structure defining a space for receiving said energy source modules, wherein at least one of said energy source modules is a pressurized vessel containing a fluid.
2. The modular system according to claim 1, wherein at least one of said energy source modules is a traction battery pack.
3. The modular system according to claim 1, wherein at least one of said energy source modules is cuboid.
4. The modular system according to claim 3, wherein the at least one pressurized vessel is cuboid.
5. The modular system according to claim 1, wherein a cross-sectional area of one of said energy source modules is approximately a multiple of any cross-sectional area of any other one of said energy source modules.
6. The modular system according to claim 1, wherein at least one of said at least one pressurized vessel has a first larger cuboid portion and a second smaller portion projecting from the first cuboid portion.
7. The modular system according to claim 1, further comprising bushings for mounting said energy source modules to the support structure in order to allow a certain amount of relative motion between the support structure and the energy source modules when mounted.
8. The modular system according to claim 7, wherein said bushings comprises first bushings having a first stiffness and second bushings having a second stiffness which is different from the first stiffness, wherein said first bushings are configured for mounting energy source modules in the form of pressurized vessels and wherein said second bushings are configured for mounting energy source modules in the form of traction battery packs.
9. The modular system according to claim 1, wherein said support structure is in the form of an open cage structure provided with brackets for connecting the support structure to the chassis.
10. The modular system according to claim 1, wherein the fluid contained in said pressurized vessel is selected from the group consisting of: hydrogen, in gaseous state or liquid state, petroleum gas, natural gas, and non-fuel gas, such as air.
11. A vehicle comprising a modular system according to claim 1, wherein the support structure is connected to a chassis of the vehicle, wherein energy source modules are provided in the support structure, wherein at least one of said energy source modules is a pressurized vessel containing a fluid.
12. A method of installing, to a vehicle chassis, energy source modules for a modular system according to claim 1, comprising: providing the vehicle chassis on a main assembly line, connecting a support structure to the vehicle chassis, the support structure defining a space for receiving said energy source modules, providing, on a first sub-assembly line, a first type of said energy source modules with connecting components for enabling said first type of energy source modules to be connected to or included in a propulsion system of a vehicle which includes said vehicle chassis, providing, on a second sub-assembly line, a second type of said energy source modules with connecting components for enabling said second type of energy source modules to be connected to or included in said propulsion system of said vehicle, said second type being a pressurized vessel containing a fluid, selecting a number of energy source modules of the first type and a number of energy source modules of the second type, and mounting them to the support structure on the main assembly line.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] With reference to the appended drawings, below follows a more detailed description of embodiments of the invention cited as examples.
[0051] In the drawings:
[0052] FIG. 1 illustrates a vehicle for which at least some exemplary embodiments of the invention may be implemented.
[0053] FIG. 2 illustrates a support structure of a modular system in accordance with at least one exemplary embodiment of the invention.
[0054] FIG. 3 illustrates a modular system in accordance with at least one exemplary embodiment of the invention.
[0055] FIGS. 4a-4c schematically illustrate some different configurations that are possible to install in accordance with at least some exemplary embodiments of the invention.
[0056] FIGS. 5a-5b schematically illustrate that a support structure is able to receive energy source modules of different dimensions, in accordance with at least some exemplary embodiments of the invention.
[0057] FIG. 6 schematically illustrates a method according to at least one exemplary embodiment of the invention.
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS OF THE INVENTION
[0058] The invention will now be described more fully hereinafter with reference to the accompanying drawings, in which certain aspects of the invention are shown. The invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments and aspects set forth herein; rather, the embodiments are provided by way of example so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
[0059] Accordingly, it is to be understood that the present invention is not limited to the embodiments described herein and illustrated in the drawings; rather, the skilled person will recognize that many changes and modifications may be made within the scope of the appended claims. Like reference numerals refer to like elements throughout the description.
[0060] FIG. 1 illustrates a vehicle for which at least some exemplary embodiments of the invention may be implemented. Although the vehicle 1 is illustrated in the form of a truck, other types of vehicles, such as busses, construction equipment, trailers, passenger cars or even boats may be provided in accordance with the invention. The truck (vehicle 1) comprises a cab 2 in which a driver may operate the vehicle 1. The vehicle 1 comprises a frame structure, i.e. a chassis 4 to which a modular system according to embodiments of the present invention may be connected (not shown in FIG. 1). The modular system may, for example, be installed behind the cab 2. In other exemplary embodiments, the modular system, and in particular the support structure of the modular system, may be installed laterally of frame rails of the chassis 4.
[0061] FIG. 2 illustrates schematically a support structure 10 of a modular system in accordance with at least one exemplary embodiment of the invention. The support structure 10 is herein illustrated as an open cage structure for receiving energy source modules. In the illustrated exemplary embodiment, the support structure 10 is a two-sided support structure, having a first part 10a configured to be located on the left side of a vehicle chassis and a second part 10b configured to be located on the right side of the chassis. The first part 10a and the second part 10b are interconnected by connecting elements 12 (only one shown in FIG. 2), which may extend underneath the chassis. Although the connecting elements 12 are configured to extend underneath the chassis, the first and the second parts 10a, 10b will be located generally laterally of the chassis, i.e. on respective sides thereof. It should be understood that in other exemplary embodiments, the support structure 10 may have only one part, and does not necessarily need to be connected laterally of the chassis, as other locations may be more appropriate depending on the configuration of the individual vehicle to which a support structure 10 is to be installed. In the illustrated exemplary embodiments, the support structure 10 is provide with brackets 14 for attaching the support structure 10 to the chassis. Suitable fastening elements, such as bolts, may be driven through the brackets 14 and the chassis to tighten the support structure 10 to the chassis. As illustrated in FIG. 2, the support structure 10 may be provided with partition portions 16 for dividing the available space into individual compartments 18. This reduces the risk of the energy source modules inadvertently bumping into each other during driving. In the present illustration, there are three compartments 18 on either side, which means that the support structure 10 is prepared for receiving six energy source modules. Although the compartments 18 have been illustrated as having substantially the same dimensions, many variations are conceivable. For instance, by removing one partition portion 16, you create a compartment which is approximately double the size of the other compartments 18, which can thus receive an energy source module being twice as large as the others. In other exemplary embodiments, the location of the partition portions may be selectable, such that different sizes of individual compartments may be provided. The flexibility of choosing different sizes of energy source modules is, in particular, advantageous for energy source modules in the form of pressurized vessels containing gas or liquid, as depending on the requirement of the volume of the fluid to be installed, it may be more practical and economical (and better utilization of available space) to install a large vessel compared to several small ones.
[0062] The modular system may suitably comprise bushings 19 for mounting the energy source modules to the support structure in order to allow a certain amount of relative motion between the support structure source and the energy source modules when mounted. The bushings may comprise first bushings having a first stiffness and second bushings having a second stiffness which is different from the first stiffness, wherein said first bushings are configured for mounting energy source modules in the form of pressurized vessels and wherein said second bushings are configured for mounting energy source modules in the form of traction battery packs.
[0063] FIG. 3 illustrates a modular system 100 in accordance with at least one exemplary embodiment of the invention. In this exemplary embodiment the modular system 100 comprises the support structure 10 illustrated in FIG. 2, however, as may be readily understood, in other exemplary embodiments the modular system 100 may have a different support structure. The modular system 100 also comprises a plurality of energy source modules 20, 30, 40 configured to be connected to or included in a propulsion system of the vehicle to which the support structure 10 is mounted. Each one of the energy source modules 20, 30, 40 has a rectangular cross-section. In particular, it should be noted that at least one of said energy source modules 20, 30 is a pressurized vessel containing a fluid, such as a gas or a liquid. This is in contrast to traditional configurations of pressurized vessels, which traditionally have been provided in the form of circular cylindrical containers. Such pressurized vessels require specific handling, equipment and tools when mounting them to a vehicle in a factory. By instead providing the pressurized vessels 20, 30 with rectangular cross-section, the installation and mounting is greatly facilitated as the same equipment and tools may be used as for other energy source modules 40, such as traction battery packs, that also have rectangular cross section. It should be noted that the interior of the pressurized vessel may include rounded interior walls, as long as the outer configuration has a rectangular cross-section, since the outer configuration (not the inner configuration) is the facilitating factor in the installation process at a factory.
[0064] In the illustrated exemplary embodiment, there are shown six energy source modules 20, 30, 40, two of which are in the form of traction battery packs 40, and the remaining four are in the form of pressurized vessels 20, 30 containing a fluid, such as hydrogen in gaseous or liquid state. As illustrated in FIG. 3, the energy source modules may come in different sizes and different formfactors, but they all have a rectangular cross-section.
[0065] According to at least some exemplary embodiments of the present disclosure, each energy source module 20, 30, 40 has a rectangular cross-section in a geometrical plane P which is perpendicular to the pitch axis of the vehicle, i.e. a plane which extends in the vertical and longitudinal direction of the vehicle. The energy source modules 20, 30, 40 will normally be provided with different connecting elements, routings, etc. which means that they will have a designated orientation in which they should be mounted to the support structure and thus relative to the vehicle as well. Therefore, according to at least some exemplary embodiments, each energy source module 20, 30, 40 has a designated inboard side configured to face towards the centre of the vehicle when installed, a designated outboard side configured to face away from the centre of the vehicle. Thus, according to at least some exemplary embodiments, each energy source module 20, 30, 40 has a rectangular cross-section in a geometrical plane P which is parallel to the inboard and or outboard side of the energy source module. It should be noted that energy source modules 20, 30, 40 may have a rectangular cross-section in other planes and directions as well. For instance, in FIG. 3 each one of the two traction battery packs 40 has a substantially cuboid shape, and thus has rectangular cross-section in three orthogonal directions/planes. It should also be noted that several energy source modules may be interconnected such that one of the interconnected energy source module provides a common connection to the propulsion system. For instance, several pressurized vessels may be interconnected by suitable piping, and only one of them has a connection for providing the fluid to the propulsion system.
[0066] As illustrated in FIG. 3, a first type of the pressurized vessels 20 is, similarly to the traction battery packs 40, substantially cuboid. The other three pressurized vessels 30 represent a second type and are here illustrated as having a different formfactor. These other three traction battery packs are illustrated as including the basic shape of the cuboid of the first type, but has an additional shape in the form of a smaller projection. Thus, each one of the illustrated second type of pressurized vessels has a first larger cuboid portion 30a and a second smaller portion 30b projecting from the first cuboid portion 30a. The second portion 30b is configured to fit underneath the frame rails of the chassis, while the cuboid portion 30a is configured to be located laterally of the chassis. In this way, the smaller projecting portions 30b add extra available fluid volume that can be stored. For example, the cuboid first type of pressurized vessel 20 may contain 270 litres of fluid, while each one of the larger second type pressurized vessels 30 may contain 420 litres. Other volumes are of course conceivable as well.
[0067] It may be noted that in the illustrated exemplary embodiments, the smaller projecting portions 30b also have a rectangular cross-section, at least in geometrical planes P perpendicular to the pitch axis.
[0068] It should be emphasized that FIG. 3 is merely an illustrative exemplary embodiment to give an idea of different possibilities within the scope of the present invention. It should, however, be understood that there are numerous variations possible, and the specific choice of which kinds, configurations and sizes of energy source modules that are chosen to be used for a particular vehicle may depend on the individual configuration of the vehicle, the requests of the customer, etc.
[0069] For instance, in some exemplary embodiments only cuboid pressurized vessels 20 are used. In some exemplary embodiments, only the second type of pressurized vessels 30 are used. The number of the different types of the energy source modules may also be chosen according to needs. Thus, the number of traction battery packs 40 may be more than two or may be just one.
[0070] FIGS. 4a-4c schematically illustrate some different configurations that are possible to install in accordance with at least some exemplary embodiments of the invention. The schematic illustrations represent a vertical cross-section taken perpendicular to the longitudinal direction of the vehicle. In each one of FIGS. 4a-4c there is schematically illustrated a central chassis frame 50. In each one of FIGS. 4a-4c there is illustrated an energy source module located on the left hand side of the frame 50 and an energy source module located on the right side of the frame. These figures show examples of different formfactors and setups between the left hand side and the right hand side.
[0071] FIG. 4a illustrates a traction battery pack 40 on the left hand side of the frame 50 and a gas-containing (or liquid-containing) pressurized vessel 20 on the right hand side of the frame. In this illustration, the traction battery pack 40 may have substantially equally dimensioned sides, while the pressurized vessel 20 may have a pair of opposite sides with different dimensions than the other pairs of opposite sides. However, in other exemplary embodiments, the pressurized vessel 20 may have all sides of equal dimensions, and in some exemplary embodiments the traction battery pack 40 may have a differentiating pair of opposite sides. Thus, the present general inventive concept is not limited to a specific size or overall shape of certain energy source modules. For instance, a traction battery pack 40 and a pressurized vessel 20 may, in at least some exemplary embodiments, share the same formfactor and dimensions.
[0072] In the example illustrated in FIG. 4b the pressurized vessel on the right hand side in FIG. 4a has been replaced by a differently shaped gas-containing pressure vessel 30. In FIG. 4b, a first large portion 30a of the pressurized vessel has the same formfactor as the entire pressurized vessel 20 of FIG. 4a, i.e. cuboid. However, in addition to the cuboid first large portion 30a, there is also provided a second smaller projecting portion 30b, which projects inboardly and underneath the frame 50.
[0073] FIG. 4c illustrates a further alternative in which both the left hand side and the right hand side is provided with pressurized vessels 30 having a first large portion 30a, which is cuboid, and a smaller projecting second portion 30b. Since the second smaller projecting portions 30b project from both the left hand side and the right hand side, they will normally present shorter projections than when projecting only from one side (compare with FIG. 4b).
[0074] As understood from the drawings presented herein, according to at least one exemplary embodiment, the second smaller portion projects 30b from a lower region of the first larger cuboid portion 30a.
[0075] FIGS. 5a-5b schematically illustrate that a support structure 10 is able to receive energy source modules of different dimensions, in accordance with at least some exemplary embodiments of the invention. FIG. 5a illustrates a support structure 10 which has received three energy storage modules 60 of equal size. FIG. 5b, however, illustrates that a corresponding support structure 10 has only received two energy storage modules 60, 70, one of which is approximately twice the size of the other one. Thus, according to at least one exemplary embodiment, the cross-sectional area of one of said energy source modules 70 is approximately a multiple of any cross-sectional area of any other one of said energy source modules 60. It should however, be understood that in other exemplary embodiments the size difference does not necessarily need to be a multiple of another, but other dimensions are also conceivable. For instance, in the illustrated example, if the larger one of the energy source modules 70 in FIG. 5b is reduced slightly in size, the support structure may be used for receiving other items than just energy source modules.
[0076] The various different illustrated pressurized vessels of the drawings may suitably contain a fluid selected from the group consisting of hydrogen, petroleum gas, natural gas and air, as already discussed elsewhere in this disclosure.
[0077] FIG. 6 schematically illustrates a method 1000 according to at least one exemplary embodiment of the invention. More specifically, there is illustrated a method 1000 of installing, to a vehicle chassis, energy source modules for a modular system disclosed herein. The method 1000 comprises: [0078] in a step S1, providing the vehicle chassis on a main assembly line, [0079] in a step S2, connecting a support structure to the vehicle chassis, the support structure defining a space for receiving said energy source modules, [0080] in a step S3, providing, on a first sub-assembly line, a first type of said energy source modules with connecting components for enabling said first type of energy source modules to be connected to or included in the propulsion system of the vehicle, [0081] in a step S4, providing, on a second sub-assembly line, a second type of said energy source modules with connecting components for enabling said second type of energy source modules to be connected to or included in the propulsion system of the vehicle, said second type being a pressurized vessel containing a gas, [0082] in a step S5, selecting a number of energy source modules of the first type and a number of energy source modules of the second type, and mounting them to the support structure on the main assembly line.
[0083] It should be noted that the steps do not necessarily have to be carried out in the listed order. For instance, steps S3 and S4 may be performed simultaneously. Indeed steps S3 and S4 may suitably be performed simultaneously with steps S1 and S2.
[0084] It is to be understood that the present invention is not limited to the embodiments described above and illustrated in the drawings; rather, the skilled person will recognize that many changes and modifications may be made within the scope of the appended claims.
