DE102022123941A1 - METHOD FOR CONVERTING A VEHICLE, A DRIVE AXLE FOR A VEHICLE AND A VEHICLE - Google Patents

Abstract

The invention relates to a method for converting a vehicle to an electric drive, the vehicle having a drive axle with a wheel axle, the wheel axle having at least one wheel suspension with a wheel and a braking system assigned to the respective wheel on its two opposite ends, the opposite wheels via a cardan shaft and a transmission with a differential and a plurality of gears, in particular a ring gear and a bevel gear, having the following steps:
- removing the cardan shaft,
- removing and a plurality of gears, in particular a ring gear and a bevel gear,
- Inserting and connecting an electrically controllable gearbox,
- inserting and connecting at least one electric drive to drive the wheels,
- Inserting and connecting at least one energy storage and/or energy converter, the electric drive and the transmission being connected to one another in such a way that the opposite wheels are driven.

Description

The invention relates to a method for converting a vehicle, the vehicle belonging to the group of commercial vehicles, special vehicles and mobile work machines, a drive axle for a vehicle and a vehicle.

Discussions about the topics of environmental protection and electromobility are currently omnipresent. It is a fact that electric vehicles are “emission-free” during operation. Compared to combustion engines, they do not produce any direct emissions.

Various solutions are known from the prior art as to how motor vehicles or vehicles can be operated fully electric or hybrid. For this purpose, the design of the motor vehicle or vehicle in question is often adapted to the type of drive or planned this way from the outset. Accordingly, a new vehicle concept and a new vehicle are created here every time.

However, from an ecological point of view, it is not sustainable to constantly produce a new vehicle just to get a fully electric or hybrid vehicle. Because every vehicle that has to be produced new does not make ecological sense.

The present invention is based on the object of providing an improvement or an alternative to the prior art.

• - Entnehmen der Kardanwelle,
• - Entnehmen und einer Mehrzahl an Zahnrädern, insbesondere einem Tellerrad und einem Kegelrad,
• - Einsetzen und Anschließen eines elektrisch ansteuerbaren Getriebes,
• - Einsetzen und Anschließen zumindest eines elektrischen Antriebs zum Antrieb der Räder,
• - Einsetzen und Anschließen zumindest eines Energiespeichers und/oder
• - Energiewandlers,

wobei der elektrische Antrieb und das Getriebe so miteinander verbunden sind, dass die gegenüberliegenden Räder angetrieben werden.According to a first aspect, the stated task solves a method for converting a vehicle to an electric drive, the vehicle having a drive axle with a wheel axle, the wheel axle having at least one wheel suspension with a wheel and one assigned to the respective wheel on its two opposite ends Braking system, the opposing wheels having a cardan shaft and a transmission with a differential and a plurality of gears, in particular a ring gear and a bevel gear, having the following steps:

• - removing the cardan shaft,
• - removing and a plurality of gears, in particular a ring gear and a bevel gear,
• - Inserting and connecting an electrically controllable gearbox,
• - inserting and connecting at least one electric drive to drive the wheels,
• - Inserting and connecting at least one energy storage device and/or
• - energy converter,

whereby the electric drive and the transmission are connected to one another in such a way that the opposite wheels are driven.

• Es sei ausdrücklich darauf hingewiesen, dass im Rahmen der hier vorliegenden Patentanmeldung unbestimmte Artikel und unbestimmte Zahlenangaben wie „ein...“, „zwei...“ usw. im Regelfall als mindestens-Angaben zu verstehen sein sollen, also als „mindestens ein...“, „mindestens zwei...“ usw., sofern sich nicht etwa aus dem Kontext oder dem konkreten Text einer bestimmten Stelle ergibt, dass etwa dort nur „genau ein...“, „genau zwei...“ usw. gemeint sein soll. Weiterhin sind alle Zahlenangaben sowie Angaben zu Verfahrensparametern und/oder Vorrichtungsparametern im technischen Sinne zu verstehen, d.h. als mit den üblichen Toleranzen versehen zu verstehen. Auch aus der expliziten Angabe der Einschränkung „wenigstens“ oder „mindestens“ o.ä. darf nicht geschlossen werden, dass bei der einfachen Verwendung von „ein“, also ohne die Angabe von „wenigstens“ o.ä., ein „genau ein“ gemeint ist.

The following is explained conceptually:

• It should be expressly pointed out that in the context of the present patent application, indefinite articles and indefinite numbers such as "one...", "two..." etc. should generally be understood as at least information, i.e. as "at least one ...", "at least two..." etc., unless the context or the specific text of a particular passage shows that there is only "exactly one...", "exactly two..." etc. should be meant. Furthermore, all numerical information as well as information on process parameters and/or device parameters are to be understood in the technical sense, that is to say as provided with the usual tolerances. Even from the explicit specification of the restriction “at least” or “at least” or similar, it should not be concluded that the simple use of “a”, i.e. without specifying “at least” or similar, means “exactly one”. " is meant.

In this case, conversion means that an existing or used vehicle serves as the basis for electrifying it. This means that vehicles that have already been manufactured can continue to be used without having to produce a new vehicle with an adapted vehicle concept to create an electric vehicle.

On the one hand, this reduces the planning effort and costs for new production and, on the other hand, it increases the sustainability of vehicles through further use. Increasing sustainability reduces CO2 emissions.

The method envisages that the elements typical of combustion engines, i.e. the cardan shaft, and a plurality of gears from the transmission, are removed and replaced by a new system for electric driving.

An electrically controllable gearbox is then provided for this purpose. It is conceivable that the controllable transmission continues to use one or more gears from the previous transmission and the differential. This ensures the smooth functioning of the transmission and the drive of the wheels.

The other components, such as at least one electric drive to drive the wheels and the energy storage and/or Ener gy converter inserted and connected. Connecting means that the elements are connected to one another in such a way that they are operatively connected so that the opposite wheels are driven.

In order to be able to supply the electric drive with energy, a lithium-ion battery can be provided as an energy storage device or a hydrogen or direct methanol-based fuel cell can be provided as an energy converter.

For example, it is conceivable that the at least one electric drive is used in such a way that a shaft of the electric drive is arranged parallel or substantially parallel to the wheel axle.

This means that the electric drive and the transmission work efficiently together as the gear ratio is reduced. Furthermore, installation space can be saved because the electric drive can be integrated more compactly due to the axle arrangement.

Within the scope of the invention, it is conceivable that the at least one electric drive is integrated into a gear housing of the transmission when inserted.

The integration of the electric drive into the housing allows for a space-saving and compact design of the new drive train. Furthermore, the unit consisting of the transmission and electric drive is easier to handle in order to exchange or convert it.

It is conceivable that an electrically controllable two-speed transmission is used.

The use of an electrically controllable two-speed transmission enables the at least one electric drive to be made smaller without the efficiency or performance of the entire system suffering. Accordingly, a two-speed transmission has a positive effect on installation space and efficiency.

Furthermore, it is possible for a housing of the transmission to be used at least partially, in particular completely, as a transmission housing of the electrically controllable transmission.

Existing structural elements, such as a housing cover, can advantageously be reused. This means that the wheel axle does not need to be converted or replaced. In addition, this can prevent waste and increase sustainability.

Furthermore, it is conceivable that the housing of the electrically controllable transmission is connected to the housing of the transmission and/or the wheel axle via a transmission adapter.

The adapter allows as many parts of the previous gearbox to be reused as possible. Furthermore, the adapter can be used to compensate for size differences between the existing parts and the new transmission parts. This increases the variability of the housing or transmission parts to be converted or used.

According to a second aspect of the invention, the stated object solves a drive axle for a vehicle, the drive axle being converted to an electric drive according to a method described above for converting a vehicle, having a wheel axle with at least one wheel suspension at the opposite ends of the wheel axle, wherein at least one wheel with a brake system is assigned to the at least one wheel suspension, an electrically controllable transmission, wherein a transmission housing of the electrically controllable transmission is designed to be at least partially, in particular completely, replaced in a conversion and / or replacement process, and at least one electric drive, wherein the electric drive is in a drive housing, wherein the drive housing is designed to be replaced in a conversion and/or replacement process, and at least one energy storage and/or energy converter, wherein the energy storage and/or energy converter is in a housing is, wherein the housing is designed to be replaced in a conversion and / or replacement process.

The electric drive in its drive housing and the energy storage and/or energy converter in the associated housing are designed so that they are easy to handle during the conversion process. This also allows for easy replacement during a maintenance process. In the present case, it is assumed that when the drive housing is replaced, the electric drive is also replaced or at least removed. This can involve replacing a drive housing and/or an electric drive.

In the present case, conversion means that an existing or used vehicle serves as the basis for electrifying it. This means that vehicles that have already been manufactured can continue to be used without having to produce a new vehicle with an adapted vehicle concept to create an electric vehicle.

On the one hand, this reduces the planning effort and costs for new production and, on the other hand, it increases the sustainability of vehicles through further use. Increasing sustainability reduces CO2 emissions.

In order to be able to supply the electric drive with energy, a lithium-ion battery can be provided as an energy storage device or a hydrogen-based or direct methanol-based fuel cell can be provided as an energy converter. These allow an efficient power supply. Furthermore, it is conceivable that these are also freely interchangeable with one another. This means that a hydrogen-based fuel cell could be exchanged for a direct methanol fuel cell or a lithium-ion battery in a maintenance process, or vice versa.

For this purpose, the individual elements, i.e. the electric drive and the transmission and the energy storage, can have a modular structure. This increases the variability of the individual components and allows the respective drive axle to be designed to suit the needs of the customer and the location of the vehicle.

It is conceivable that a shaft of the at least one electric drive is arranged parallel or substantially parallel to the wheel axis.

This means that the electric drive and the transmission work efficiently together because the gear ratio can be reduced. Furthermore, installation space can be saved because the electric drive can be integrated more compactly due to the axle arrangement. It is also advantageous that the accessibility of the electric drive is improved, which makes it easier to repair or replace the electric drive during a maintenance process.

Within the scope of the invention, it is conceivable that the transmission housing is designed to accommodate at least one electric drive with a drive housing, in particular two electric drives with a drive housing.

As a result, at least one electric drive, in particular two electric drives, can be integrated to save space in order to save installation space. In addition, handling during the conversion or replacement process is simplified.

Furthermore, it is conceivable that the transmission is an electric two-speed transmission.

The use of an electrically controllable two-speed transmission enables the at least one electric drive to be made smaller without the efficiency or performance of the entire system suffering. Accordingly, a two-speed transmission has a positive effect on installation space and efficiency.

Within the scope of the invention, it is conceivable that a gearbox adapter is provided, which is designed to connect the gearbox of the electrically controllable gearbox to the wheel axle.

The adapter allows as many parts of the previous gearbox to be reused as possible. Furthermore, the adapter can be used to compensate for size differences between the existing parts and the new transmission parts. This increases the variability of the housing or transmission parts to be converted or used.

According to a third aspect of the invention, the problem solved is a vehicle with a drive axle for a vehicle that has been converted to an electric drive according to the method described above for converting a vehicle to an electric drive.

It is also conceivable that at least one electric drive is arranged in front of the wheel axle and/or after the wheel axle in the direction of travel. This allows the drive to be adapted depending on the vehicle on which the conversion is based.

The direction of travel is understood to mean the direction of travel in normal operation, i.e. in the longitudinal direction towards the driver's cab.

Within the scope of the invention, it is conceivable that the wheel axle is the front axle and/or rear axle.

• 1 in schematischer Darstellung ein Verfahren zum Umrüsten eines Fahrzeuges auf einen elektrischen Antrieb,
• 2 in schematischer Darstellung eine Antriebsachse nach dem Umrüsten,
• 3 in schematischer Darstellung ein umgerüstetes Fahrzeug.

The invention will be explained in more detail below using exemplary embodiments with reference to the drawings. Show there

• 1 a schematic representation of a method for converting a vehicle to an electric drive,
• 2 a schematic representation of a drive axle after conversion,
• 3 a schematic representation of a converted vehicle.

• - Entnehmen 110 der Kardanwelle,
• - Entnehmen 120 einer Mehrzahl an Zahnrädern, insbesondere einem Tellerrad und einem Kegelrad,
• - Einsetzen 130 und Anschließen 140 eines elektrisch ansteuerbaren Getriebes,
• - Einsetzen 150 und Anschließen 160 zumindest eines Elektrischer Antriebs zum Antrieb der Räder,
• - Einsetzen 170 und Anschließen 180 zumindest eines Energiespeichers und/oder Energiewandlers,

wobei der elektrische Antrieb 2 und das Getriebe 8 so miteinander verbunden sind, dass die gegenüberliegenden Räder 6 angetrieben werden. 1 shows a method 100 for converting a vehicle 1 to an electric drive 2, the vehicle 1 having a drive axle 3 with a wheel axle 4, the wheel axle 4 having at least one wheel suspension 5 with a wheel 6 on its two opposite ends and a brake system 7 assigned to the respective wheel 6, the opposite wheels 6 having a cardan shaft and a transmission with a differential and a plurality of gears, in particular a ring gear and a bevel gear, having the following steps:

• - Remove 110 of the cardan shaft,
• - Removing 120 a plurality of gears, in particular a ring gear and a bevel gear,
• - inserting 130 and connecting 140 an electrically controllable transmission,
• - inserting 150 and connecting 160 at least one electric drive to drive the wheels,
• - inserting 170 and connecting 180 at least one energy storage and/or energy converter,

wherein the electric drive 2 and the transmission 8 are connected to one another in such a way that the opposite wheels 6 are driven.

When inserting 150 the at least one electric drive 2, care is taken to ensure that its shaft 9 is arranged parallel to the wheel axle 4 in order to build as compactly as possible.

At the same time, the electric drive 2 or the electric drives 2 are integrated into the transmission housing 10 of the transmission 8. This also makes it easier to arrange the shaft of the electric drive 2 parallel to the wheel axle 4, since the bearing points are already provided. The electrically controllable transmission 8 is an electrically controllable two-speed transmission 14.

To increase sustainability, a part, here the transmission cover 11 on the side of the drive axle 3 of the housing of the previous transmission, is at least partially, in particular completely, used as a transmission housing 10 of the electrically controllable transmission 8.

The transmission housing 10 of the electrically controllable transmission 8 is connected to the housing of the previous or converted transmission and/or the wheel axle 4 via a transmission adapter 12.

In 2 the drive axle 3 for a vehicle 1 is shown. The drive axle 3 is according to a method 1 converted. The converted drive axle 3 has a wheel axle 4, each with at least one wheel suspension 5 at the opposite ends of the wheel axle 4, with the at least one wheel suspension 5 being assigned at least one wheel 6 with a braking system 7, an electrically controllable transmission 8, with a transmission housing 10 of the electrically controllable transmission 8 is designed to be at least partially, in particular completely, replaced in a conversion and / or replacement process, and at least one electric drive 2 in a drive housing 13, the drive housing 13 being designed in a conversion and / or Replacement process to be replaced, and at least one energy storage 15 and / or energy converter 15, wherein the energy storage 15 and / or energy converter 15 is in a housing, wherein the housing is designed to be replaced in a conversion and / or replacement process.

A shaft 9 of the at least one electric drive 2 is arranged parallel or essentially parallel to the wheel axle 4. Furthermore, the transmission housing 10 is designed so that it accommodates at least one electric drive 2. In the present exemplary embodiment, it accommodates two electric drives 2.

Furthermore, the electrically controllable transmission is 8 in 2 an electric two-speed gearbox 14. This is designed so that it accommodates the two electric drives 2 and at the same time saves space. For this reason, the transmission housing 10 of the two-speed transmission 14 is connected to the wheel axle 4 using a transmission housing adapter 12.

In 3 is a vehicle 1 with one according to the method 1 converted drive axle 3 2 shown. The vehicle 1 shows a semitrailer 16 with a front axle 17 and a rear axle 18, as well as a driver's cab 19 with a wheel axle 4. Both the front axle 17 and the wheel axle 4 of the driver's cab 19 can be driven. In the present example, a rear axle 18 was converted. It is also conceivable here to convert the front axle 17 of the trailer 16 as well as the wheel axle 4 of the driver's cab 19. If only one axle is converted, it is a hybrid, if the other drive axles 3 are also converted, the vehicle 1 can be operated fully electrically.

Both electric drives 2 are arranged in the direction of travel after the wheel axle 4. It would also be conceivable to arrange the electric drives 2 in front of the wheel axle 4.

The embodiments shown here represent only examples of the present invention and should therefore not be construed as limiting. Alternative embodiments contemplated by those skilled in the art are more similar measured within the scope of the present invention.

List of reference symbols used

100

Procedure for conversion

110

Removing the cardan shaft

120

Removing a number of gears

130

Insertion of an electrically controllable gearbox

140

Connecting an electrically controllable gearbox

150

Using at least one electric motor

160

Connecting at least one electric motor

170

Inserting at least one energy storage and/or energy converter

180

Connecting at least one energy storage and/or energy converter

1

vehicle

2

electric drive

3

Drive axle

4

wheel axle

5

suspension

6

wheel

7

Braking system

8th

Electrically controllable transmission

9

Wave

10

Gearbox housing

11

Gearbox cover

12

Gearbox adapter

13

Drive housing

14

Two-speed gearbox

15

Energy storage and/or energy converter

16

semi-trailer

17

Front axle

18

rear axle

19

Cab

Claims (14)

Method (100) for converting a vehicle (1), the vehicle belonging to the group of commercial vehicles, special vehicles and mobile work machines, to an electric drive (2), the commercial vehicle (1) having a drive axle (3) with a wheel axle ( 4), wherein the wheel axle (4) has at least one wheel suspension (5) on its two opposite ends with a wheel (6) and a braking system (7) assigned to the respective wheel (6), the opposite wheels (6) via a cardan shaft and a transmission with a differential and a plurality of gears, in particular a ring gear and a bevel gear, having the following steps: - removing (110) the cardan shaft, - Removing (120) and a plurality of gears, in particular a ring gear and a bevel gear, - inserting (130) and connecting (140) an electrically controllable transmission (8), - inserting (150) and connecting (160) at least one electric drive to drive the wheels, - Inserting (170) and connecting (180) at least one energy storage device (15) and/or energy converter (15), the electric drive (2) and the electrically controllable transmission (8) being connected to one another in such a way that the opposite wheels (6 ) are driven. Procedure (100) according to Claim 1 , characterized in that the at least one electric drive (2) is used so that a shaft of the electric drive (2) is arranged parallel or substantially parallel to the wheel axle (4). Method (100) according to one of the preceding claims, characterized in that the at least one electric drive (2) is integrated into a gear housing (10) of the electrically controllable gear (8) when inserted. Method (100) according to one of the preceding claims, characterized in that an electrically controllable two-speed transmission (14) is used. Method (100) according to one of the preceding claims, characterized in that a housing of the transmission is used at least partially, in particular completely, as a transmission housing (10) of the electrically controllable transmission (8). Method (100) according to one of the preceding claims, characterized in that the transmission housing (10) of the electrically controllable transmission (8) is connected to the housing of the transmission and/or the wheel axle (4) via a transmission adapter (11). Drive axle (3) for a vehicle (1), the vehicle belonging to the group of commercial vehicles, special vehicles and mobile work machines, the drive axle (3) being converted according to a method according to the preceding claims, having a wheel axle (4) with each at least one wheel suspension (5) at the opposite ends of the wheel axle (4), the at least one wheel suspension (5) being assigned at least one wheel (6) with a braking system (7), an electrically controllable transmission (8), wherein a transmission housing (10) of the electrically controllable transmission (8) is designed to be at least partially, in particular completely, replaced in a conversion and / or replacement process, and at least one electric drive (2), the electric drive (2) being in a drive housing (13), wherein the drive housing (13) is designed to be replaced in a conversion and/or replacement process, and at least one energy storage (15) and/or energy converter (15), wherein the energy storage and/or energy converter is in one Housing is, wherein the housing is designed to be replaced in a conversion and / or replacement process. Drive axles (3) oh Claim 7 , characterized in that a shaft (9) of the at least one electric drive (2) is arranged parallel or substantially to the wheel axle (4). Drive axle (3). Claim 7 or 8th , characterized in that the transmission housing (10) is designed to accommodate at least one electric drive (2) with a drive housing (13), in particular two electric drives (2) with a drive housing (13). Drive axle (3). Claim 7 until 9 , characterized in that the transmission is an electric two-speed transmission (14). Drive axle (3). Claim 7 until 10 , characterized in that a gearbox adapter (12) is provided, which is designed to connect the gearbox (10) of the electrically controllable gearbox (8) to the wheel axle (4). Vehicle (1) with one according to the procedure according to Claims 1 until 6 converted drive axle (3) according to one of the Claims 7 until 11 . Vehicle (1) after Claim 12 , characterized in that the at least one electric drive (2) is arranged in front of the wheel axle (4) and/or after the wheel axle (4) in the direction of travel. Vehicle (1) after Claim 12 or 13 , characterized in that the wheel axle (4) is the front axle (17) and/or rear axle (18).

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