TRANSPORT TRUCK WITH MODULAR DRIVE SYSTEM

Description

1 / 47 TRANSPORT TRUCK WITH MODULAR DRIVE SYSTEM CROSS-REFERENCE TO RELATED REQUESTS

[001] This application claims priority to U.S. Provisional Patent Application No. 63 / 494,229, filed April 4, 2023; and to U.S. Provisional Patent Application No. 63 / 494,230, filed April 4, 2023; and to U.S. Non-Provisional Patent Application Serial No. 18 / 626,222, filed April 3, 2024; and to U.S. Non-Provisional Patent Application Serial No. 18 / 626,243, filed April 3, 2024; all of which are incorporated herein by reference. BACKGROUND

[002] Transport trucks are large vehicles that transport heavy loads. Transport trucks may be used during large-scale mining or construction operations. Operations that use transport trucks may have fleets of various types of transport trucks operating continuously. Thus, during operations, an operator may be continuously servicing different transport trucks of various makes, models, and design specifications.

[003] Transport trucks can consume an undesirable amount of fuel and produce an undesirable amount of emissions in the form of carbon dioxide, greenhouse gases, and other emissions. Therefore, it is desirable to reduce the amount of fuel consumed by a transport truck and to otherwise reduce the greenhouse gas emissions from the transport truck. SUMMARY

[004] One or more embodiments provide a device. The device includes a junction configured to receive electrical power from Petition 870250089714, dated 02 / 10 / 2025, page 9 / 92 2 / 47 a power source. The device also includes a power management system connected to the junction, the power management system configured to transform electrical energy into transformed electrical energy. The device also includes a managed device connected to the power management system. The managed device is configured to consume the transformed electrical energy. The power management system includes several modules. Each module is directly connected to at least one other module. Each module is interchangeable with another module. Each module includes one or more switches to control an operating mode of each module. One or more switches in each module are configured to control an electrical interface between the power management system and a number of electrical components of the device.The electrical components, including at least the managed device.

[005] One or more embodiments provide a vehicle. The vehicle includes a chassis and an engine connected to the chassis. The vehicle also includes an alternator connected to the engine and a drive system connected to the alternator. The vehicle also includes a series of wheel motors connected to the drive system. The vehicle also includes a series of wheels connected to the wheel motors. The drive system includes a series of modules. Each of the modules is directly connected to at least one other module of the modules. Each of the modules is interchangeable with another of the modules. Each of the modules includes one or more switches to control an operating mode of each of the modules. One or more switches of each of the modules are configured to control an electrical interface between the drive system and the electrical components of the vehicle, the electrical components including at least the wheel motors. Petition 870250089714, dated 02 / 10 / 2025, page 10 / 92 3 / 47

[006] One or more embodiments provide a method of adapting a vehicle including a chassis, a motor connected to the chassis, an alternator connected to the motor, a transmission connected to the motor, and a series of wheels connected to the chassis. The method includes removing the transmission and connecting a drive system to the chassis and alternator. The method also includes connecting a series of wheel motors to the wheels and drive system. The drive system includes a series of modules. Each module is directly connected to at least one other module of the modules. Each module is interchangeable with another module. Each module includes one or more switches to control an operating mode of each module. One or more switches of each module are configured to control an electrical interface between the drive system and the vehicle's electrical components, the electrical components including at least the wheel motors.

[007] Other aspects of one or more embodiments will become apparent from the following description and the appended claims. BRIEF DESCRIPTION OF THE FIGURES

[008] FIG. 1 shows an example of a transport truck, according to one or more modes.

[009] FIG. 2 shows a block representation of a transport truck with a modular drive system, according to one or more modalities.

[0010] FIG. 3 shows a component connection arrangement for a transport truck with a modular drive system, according to one or more modalities.

[0011] FIGS. 4, 5, 6 and 7 show examples of modular drive system arrangements for a transport truck, according to one or more embodiments. Petition 870250089714, dated 02 / 10 / 2025, page 11 / 92 4 / 47

[0012] FIGS. 8, 9, 10, 11, 12, 13 and 14 show exemplary modules, in various arrangements, for a modular drive system in a transport truck, according to one or more embodiments.

[0013] FIG. 15 shows an electrical wiring diagram for a transport truck with a modular drive system, according to one or more modalities.

[0014] FIG. 16 shows a method for adapting a vehicle with a combustion engine to a vehicle with a modular drive system, according to one or more embodiments.

[0015] FIG. 17 shows a device with a power management system that uses one or more modules, as described in this document, according to one or more embodiments.

[0016] Similar elements in the various figures are indicated by similar reference numbers for consistency. DETAILED DESCRIPTION

[0017] In general, the embodiments are directed at haul trucks with a modular drive system that works in conjunction with a combustion engine and wheel motors to power the truck. One or more embodiments also include methods and devices for adapting many different types of haul trucks to operate as haul trucks with modular drive systems. Thus, one or more embodiments refer to a type of hybrid haul truck.

[0018] Because haul trucks are very expensive (millions of dollars per haul truck), replacing a fleet of traditional combustion engine haul trucks with a fleet of new electric or hybrid haul trucks can be prohibitively expensive. However, adapting an existing combustion engine haul truck to use a system... Petition 870250089714, dated 02 / 10 / 2025, page 12 / 92 5 / 47 The topic of hybrid or fully electric drive was neither practical nor economical.

[0019] Adaptation has not been practical due to the unique design of haul trucks (long drive axle (compared to automobiles), different drive axle and transmission locations (compared to smaller trucks), and other factors. For example, haul trucks are subject to extreme conditions in terms of the forces applied to a haul truck, the electrical currents used in a hybrid or electric haul truck, and the environmental wear and tear imposed under harsh mining or construction conditions. In one specific example, haul trucks may carry loads exceeding 240 tons and may operate exclusively off-road in adverse conditions at low speeds, presenting conditions that may exceed the limits and capabilities of conventional engines.

[0020] For these reasons, existing combustion-powered transport trucks remain in operation, and conversion to hybrid or electric transport trucks has been nonexistent. However, there is a growing desire in the industry to reduce carbon emissions, creating, in turn, the desire to seek solutions to adapt combustion-powered transport trucks into hybrid or electric transport trucks.

[0021] One or more embodiments address the technical challenges involved in cost-effectively adapting a haul truck to use a hybrid drive system. One or more embodiments provide a modular drive system that can be used to adapt an entire fleet of existing mixed haul truck models. The wheel motors and drive system of one or more embodiments are specifically designed to handle the large amount of torque that the drive train generates. Petition 870250089714, dated 02 / 10 / 2025, page 13 / 92 6 / 47 transport truck ment is used to transport large loads while also being small enough to fit in the available space.

[0022] In one or more embodiments, wheel motors can be connected to two or more of the wheels of the haul truck. For example, single-wheel motors can be connected to wheels on a one-by-one basis, although it is possible for a wheel motor to be attached to multiple wheels rotating in tandem. A modular drive system is installed on the haul truck. The modular drive system controls the operation of the wheel motors, which in turn drive or slowly rotate the wheels of the haul truck.

[0023] The transport truck's engine can be retained. An alternator connected to the engine can generate electrical power, which is supplied to the drive system. However, in one embodiment, physical components such as a drive shaft, differential, and drive may be removed from the transport truck being adapted, as such components will no longer be needed once the drive system and wheel motors are installed. However, in another embodiment, the drive shaft, transmission, and differential may be retained so that the transport truck can still operate without using the wheel motors. In yet another embodiment, a drive shaft motor may be installed on the engine, with the drive shaft motor connected to the transmission and differential, if the use of the wheel motors is undesirable.

[0024] A battery can be installed in the transport truck. The battery can be charged by regenerative braking via one or more of the wheel motors when the transport truck is descending or stopping. Supplemental battery charging Petition 870250089714, dated 02 / 10 / 2025, page 14 / 92 7 / 47 using an external power source is available if the terrain where the transport truck is operating does not have sufficient slope to properly charge the battery. For example, the battery can be connected to an electrical power source, the truck can be fitted with solar panels to generate electricity for the battery, etc.

[0025] One or more embodiments also contemplate a modular transport truck that can operate with multiple energy sources, such as the battery or batteries mentioned above, hydrogen fuel cells, solar cells, cart, etc. The one or more embodiments of a multi-energy source retrofit truck drive system is designed to operate diesel-electric and diesel-mechanical transport trucks of various makes and models.

[0026] The drive system of one or more modes can be presented as an adaptation kit that can be installed on various types of transport trucks to provide a modern and supported propulsion drive system. An adaptation kit allows operators to continue utilizing the investment they have made in their existing fleet while moving towards a modern system represented by one or more modes, with support for alternative energy sources to assist in fuel economy and emission reduction.

[0027] The kit, in one or more forms, can be easily added (in relation to chassis changes) to existing trucks with little or no structural changes required and at a much lower price than buying new trucks. The ease of adding the kit to trucks is achieved by using a modular structure that maximizes the reuse of the truck's main existing components, such as chassis, engine, alternator, etc. Petition 870250089714, dated 02 / 10 / 2025, page 15 / 92 8 / 47

[0028] The modularity of the system allows the kit of one or more modes to be easily configured for multiple voltages using series converters or multiple currents using parallel converters. One or more modes can benefit applications where operation from high-voltage overhead lines (i.e., a trolley arrangement) is available as an option to increase truck performance or reduce engine load for emissions purposes.

[0029] Thus, single or multi-mode haul trucks address the challenges described above. For example, single or multi-mode haul trucks have an electrical system designed (as described below) to handle much higher voltages and currents than the electrical systems used in other common hybrid applications. Single or multi-mode components can accommodate multiple power sources by adding modules to accommodate the control of each type of power source. The components are also designed to minimize structural changes applied to a haul truck when retrofitting an existing haul truck. For example, the drive system specifications for an existing truck can be evaluated. A module layout can be determined for the drive system specifications.The truck can then be adapted with any arrangement and programming of modules that are suitable to match the drive system specifications for a specific existing haul truck.

[0030] One or more embodiments may use the wheel motors to increase the performance of the haul truck by producing more power than the engine alone. One or more embodiments may use the wheel motors to allow the engine to be completely switched off while the haul truck is still operating. Petition 870250089714, dated 02 / 10 / 2025, page 16 / 92 9 / 47 Thus, one or more of these methods reduce fuel consumption and carbon emissions by reducing the amount of time the engine is running, while still optimizing engine efficiency.

[0031] One or more embodiments may be extended beyond transport trucks. For example, the modular power systems described in this document may be used in relation to electrical tools and devices other than vehicles, such as trucks. In one example, a modular power system of one or more embodiments may be used in relation to a power system for a building, a cart (other than a truck), a train, a backhoe or other construction equipment, watercraft, and many other electrical devices.

[0032] FIG. 1 shows an example of a transport truck, according to one or more embodiments. Transport truck 100 includes a chassis 102 to which wheels are attached, such as wheel 104. Note that chassis 102 may include many structural components of transport truck 100, not just the single component to which reference number 102 points in FIG. 1.

[0033] The transport truck 100 also includes a bed 106 used for transporting cargo. The transport truck 100 may include a cab 108 where a human operator can operate the transport truck 100. The transport truck 100 further includes a drive system 110 where control and electronic modules, such as the modules and electronics shown in FIGS. 4 to FIGS. 15.

[0034] FIG. 2 shows a block representation of a transport truck 200 with a modular drive system 222, according to one or more embodiments. The transport truck 200 may be the transport truck 100 of FIG. 1. The truck of Petition 870250089714, dated 02 / 10 / 2025, page 17 / 92 10 / 47 transport 200 includes a chassis 202 to which an engine 204 is connected. The engine 204 can be a combustion engine, although the engine 204 can be of different engine types. The engine 204 can also be a combination of multiple engines.

[0035] The 200 transport truck also has wheels connected to the 202 chassis, such as the 206 right front wheel, 208 left front wheel, 212 left rear wheels and 210 right rear wheels. More or fewer wheels may be present.

[0036] One or more wheel motors may be connected to the wheels of the transport truck 200. For example, the right wheel motor 214 is connected to the right rear wheels 210 and the left wheel motor 216 is connected to the left rear wheels 212. Wheel motors are electric motors capable of transmitting torque to the wheels. The transmitted torque may be in two angular directions at different times (i.e., to rotate the wheels clockwise or counterclockwise from a selected viewpoint of the wheels).

[0037] The 200 transport truck also includes an alternator 218. The alternator 218 is a component that, when rotated using rotational energy from the engine 204, generates electricity. The alternator 218 can be a source of electrical generation in the 200 transport truck, although other sources of electrical energy may be present, such as solar cells, hydrogen fuel cells, a cart drive line, etc.

[0038] The 200 transport truck may include a 220 battery connected to the 202 chassis. The 220 battery may be one or more batteries or other components for storing electrical energy, including capacitors. For example, the 220 battery may be one or more pairs of dual batteries. For example, dual batteries may be connected to an isolated DC-to-DC converter. Petition 870250089714, dated 02 / 10 / 2025, page 18 / 92 11 / 47 (DC / DC converter) and an inverter. The DC / DC converter and inverter can provide a completely independent power system for each wheel motor.

[0039] Transport truck 100 also includes a drive system 222. Drive system 222 is one or more electrical or mechanical components used to control the wheel motors (e.g., right wheel motor 214 and left wheel motor 216) and possibly other electrical systems of transport truck 200.

[0040] The 200 transport truck includes a series of modules, such as module 224, module 226, module 228, and module 230. More or fewer modules may be present. Each module is configurable to act as a different type of electrical component in the drive system 222. The modules can be configured, for example, as inverters, rectifiers, voltage converters (e.g., a DC / DC converter), alternator field static exciters (AFSEs), and other types of electrical systems. Switches in the modules, or firmware parameters or software-adjustable parameters, can determine the individual operating modes of the modules. As used in this document, the term switch, when used in relation to a module, encompasses any of the physical switches, virtual switches, firmware parameters, or software-adjustable parameters. Exemplary modules and module arrangements are shown in FIGS. 4 to 14.

[0041] The exact number of modules and the programmed functionality of the modules depend on the specific transport truck being adapted or built. The number of modules and the programmed functionality of the modules may also depend on the specific mission (i.e., set of tasks commonly assigned) of the transport truck in question. Thus, one or more modes Petition 870250089714, dated 02 / 10 / 2025, page 19 / 92 12 / 47 contemplates the determination of the system specifications for the haul truck in question, including any specifications for existing non-replacement components of the haul truck to interact with the 222 drive system. The number and programming of the modules are determined. The number of modules is then installed and subsequently programmed for the haul truck. Any motors and possibly other components may also be installed.

[0042] As an example, the modules can be arranged in one or more inverter groups. Each inverter group can be isolated from another inverter group to allow each inverter group to operate independently in the event of failure of any inverter group. This arrangement allows a diesel-electric truck to still accelerate and decelerate in the event of failure of an inverter or a motor.

[0043] The isolation of power systems in the 222 drive system can extend beyond the inverter. For example, the DC / DC converter can be one or more groups of modules that are isolated from each other. This arrangement allows the 222 drive system to completely disconnect power sources that may be faulty. The remaining power sources can still supply power to the 222 drive system. Thus, the 200 transport truck can continue to operate even in the event of a failure of a power generation system (i.e., the motor, a fuel cell, etc.).

[0044] The 200 transport truck may also include a 232 bus system. The 232 bus system may be part of one or more of the modules (i.e., module 224, module 226, module 224, or module 230). The 232 bus system is the wiring and other connections that provide electrical power to the system. Petition 870250089714, dated 02 / 10 / 2025, page 20 / 92 13 / 47 drive 222 for other components of the transport truck 200, such as the right wheel motor 214 or the left wheel motor 216.

[0045] The 200 transport truck may also include a 234 cooling system. The 234 cooling system is a system of refrigerant inlet lines and refrigerant outlet lines, along with one or more refrigerant sources. The 234 cooling system cools the 222 drive system, including the truck's modules or other electrical components. For example, the cooling system may be extended to cool the wheel motors (e.g., the right wheel motor 214 and the left wheel motor 216). Due to the high voltages and amperages in use during the operation of the 200 transport truck, excess heat may be problematic in some cases without the installation of the 234 cooling system. However, the 234 cooling system may be omitted in some configurations of the 222 drive system, depending on the specifications of the 200 transport truck.

[0046] Examples of cooling inlets and cooling outlets are shown in FIGS. 4 to 14. One or more refrigerant sources may be tanks or refrigerant line coils. The coolant may be a liquid or gas, such as, but not limited to, air, water, antifreeze, or other liquids or gases.

[0047] The drive system 222 may include components other than the modules. For example, one or more grid braking resistors 236 may be provided in the transport truck 200. Grid braking resistors 236 may be used to dissipate the extra energy produced by the wheel motor during regenerative braking that cannot be accepted by alternative energy sources such as batteries. Petition 870250089714, dated 02 / 10 / 2025, page 21 / 92 14 / 47

[0048] Grid braking resistors 236 can be connected to a blower 238. The blower 238 is one or more fans powered by the drive system 222. The blower 238 can blow air over the grid braking resistors 236 or over one or more other components of the drive system 222 in order to assist in cooling the components of the drive system 222.

[0049] The drive system 222 of the transport truck 200 may also include, or be connected to, one or more additional power sources. In the example of FIG. 2, one power source is the motor 204. However, the drive system 222 (or other parts of the transport truck 200) may include alternative power sources or additional power sources. For example, a power source for the drive system 222 may be an external high-voltage cable that allows the transport truck 200 to operate as a cart. In this case, the drive system 222 may include a cart system that maintains an electrical connection with the high-voltage cable. The bus system 232 may connect the cart system to the drive system 222, optionally through a module configured as a DC / DC converter.Other alternative or supplemental energy systems include hydrogen fuel cells, solar cells, and others, any of which are part of or connected to the 222 drive system.

[0050] The 200 transport truck may also include a 240 truck controller. The 240 truck controller is composed of electrical components, switches, controls, etc., that an operator can use to control the 200 transport truck. The 240 truck controller can control various aspects of the 222 drive system. However, the functionality of the 222 drive system modules is controlled by the switches in the modules. Petition 870250089714, dated 02 / 10 / 2025, page 22 / 92 15 / 47 los. However, in some embodiments, the 240 truck controller may include functionality to command the switches in the 222 drive system modules to change in order to alter a configuration of the electrical functionality of the modules.

[0051] The transport truck 200 may also include one or more interfaces, represented by interface 242. Interface 242 may be part of the truck controller 240. Interface 242 may include display devices (monitors, televisions, speakers, touch devices, etc.) as well as user input devices (keyboards, mice, touch screens, speakers, touch devices, etc.). Thus, interface 242 provides the user with the ability to manipulate the truck controller 240 to control various aspects of the drive system 222 or power distribution throughout the transport truck 200.

[0052] The 200 transport truck may also include one or more 244 panel controls, which may be part of the 240 truck controller. The 244 panel controls are controls for operating the truck, so as to increase or decrease the power of the wheel motors, turn the truck, control the amount of electrical energy drained from or added to the 220 battery, etc.

[0053] Thus, the 200 haul truck of one or more modes can be designed to replace existing truck electronics and controls with modern flexible components. Furthermore, one or more modes allow for additional modifications to the 200 haul truck as technology continues to evolve. For example, modular control components can be expanded with analog or digital I / O modules and fully customizable glass panel displays. The 222 drive system is designed to allow for the addition or removal of I / O as needed to upgrade haul trucks that already have it. Petition 870250089714, dated 02 / 10 / 2025, page 23 / 92 16 / 47 the drive system 222. In addition, the truck controller 240, the interface 242 or the panel controls 244 can be modified as decarbonization equipment is added without the need to replace these components.

[0054] The 222 drive system can be supplied as a kit. For example, the 222 drive system can be supplied as a base drive system that is configured to operate at the voltage and current level supported by the truck series that is most prevalent in the industry. The kit (i.e., the base system) can then be modified by adding or removing inverter clusters or other modules or components to support the specified currents or voltages of the wheel motors, alternator, or other components of the existing 200 haul truck being retrofitted.

[0055] FIG. 3 shows a component connection arrangement for a transport truck with a modular drive system, according to one or more embodiments. In particular, FIG. 3 can be considered a component connection arrangement in the transport truck 200 shown in FIG. 2. Thus, in FIG. 3, the reference numbers in common with FIG. 2 share common definitions and descriptions. Thus, the transport truck 300 of FIG. 3 can be a specific component arrangement for the transport truck 200 of FIG. 2.

[0056] However, the connections shown in FIG. 3 are not necessarily direct physical connections. Thus, for example, while the three groups of modules shown in FIG. 3 are shown as being three separate groups, it is possible to physically arrange the three groups into a grouping of modules that are all grouped into a physical grouping of modules.

[0057] The 300 transport truck in FIG. 3 includes the 204 engine. Petition 870250089714, dated 02 / 10 / 2025, page 24 / 92 17 / 47 and a left-wheel motor 216 for generating electrical power. The transport truck 300 of FIG. 3 also includes two battery groups that form battery 220 of FIG. 2. Specifically, the transport truck 300 includes battery 1 220A and battery 2 220B.

[0058] In FIG. 3, the drive system 222 of FIG. 2 includes three groups of modules. The three groups of modules are represented in FIG. 3 as module group 1 302, module group 2 304 and module group 3 306.

[0059] Module group 1 302 includes one or more modules that together act as a direct current to direct current (DC / DC) converter or DC / DC converter 308. The DC / DC converter 308 transforms voltage from a DC current. As used in this document, a DC / DC converter includes a transformer (i.e., an electrical circuit that transforms an electrical current at a first voltage into an electrical current at a second voltage). However, a converter may include one or more additional electrical circuits, of which the transformer is one electrical circuit. As an example, section 1526 in FIG. 15 shows the details of a DC / DC converter, which includes a transformer plus additional circuits.

[0060] The module group 1 302 also includes one or more modules that, together, act as a traction inverter 310. The traction inverter 310 transforms a DC current into an alternating current (AC). The word traction is used as an identifying term in relation to the traction inverter. Specifically, gearless wheel motors can be referred to as traction motors. Therefore, inverters connected to the motors can be referred to as a traction inverter, as the traction inverter transfers power to the traction motors.

[0061] Thus, as a whole, the group of modules 1 302 transforms the voltage of a DC current from battery 1 220A and then, Petition 870250089714, dated 02 / 10 / 2025, page 25 / 92 18 / 47 converts the transformed DC current into an AC current. In one embodiment, the DC / DC converter 308 is one module and the traction inverter 310 is a second module.

[0062] The 2 304 module group includes one or more modules that, together, act as another voltage converter, specifically, DC / DC converter 312. Additionally, the 2 304 module group includes one or more modules that, together, act as another traction inverter, specifically, traction inverter 314. Thus, as a whole, the 2 304 module group transforms the voltage of a DC current from battery 2 220B and then converts the transformed DC current into an AC current. In one embodiment, the DC / DC converter 312 is one module and the traction inverter 314 is a second module.

[0063] The module group 3 306 includes a DC / DC converter 316. The DC / DC converter 316 includes two or more modules that, together, act as a DC transformer, specifically a DC / DC converter 316. The DC / DC converter 316 transforms the voltage of a DC current flowing through a pantograph carriage 318 connected to the transport truck 300. In other words, the transport truck 300 derives power from two power sources: the motor 204 and the pantograph carriage 318.

[0064] Both power sources (motor 204 and pantograph carriage 318) are connected to both traction inverters (i.e., traction inverter 310 and traction inverter 314). In turn, traction inverter 310 is connected to the right wheel motor 214 and to one or more grid braking resistors 236A. Grid braking resistors 236A are part of grid braking resistors 236 in FIG. 2. Similarly, traction inverter 314 is connected to the left wheel motor 216 and to grid braking resistors 236B. Grid braking resistors 236B are part of grid braking resistors 236 in FIG. 2. Petition 870250089714, dated 02 / 10 / 2025, page 26 / 92 19 / 47

[0065] Thus, the three groups of modules shown in FIG. 3 can be used to control the power transmitted to or from the right wheel motor 214 and the left wheel motor 216. The right wheel motor 214 and the left wheel motor 216 can be controlled independently. Specifically, module group 1 302 can control the right wheel motor 214 and module group 2 304 can control the left wheel motor 216. Thus, the drive system 222 of FIG. 2 (which in FIG. 3 includes the pantograph carriage 318, battery 1 220A, battery 2 220B, module group 1 302, module group 2 304, module group 3 306, grid braking resistors 236A and grid braking resistors 236B) can be used to independently control the amount of torque applied to the rear wheels of the transport truck 300.

[0066] FIGS. 4, 5, 6 and 7 show examples of modular drive system arrangements for a transport truck, according to one or more embodiments. Going back first to FIG. 4, FIG. 4 shows a power cabinet for use in the hybrid transport truck shown in FIGS. 2 to 6, according to one or more embodiments. The power cabinet 400 enclosed within a weld 402 may be part of the drive system 222 shown in FIG. 2. The power cabinet 400 may be one or more cabinets shown in the drive system 108 of FIG. 1.

[0067] The 400 power cabinet includes two sections with components designed to perform one or more predetermined functions. Section A 404 includes one or more modules, such as the modules shown in FIG. 2. Section A 404 may also include electronic drive components and a liquid cooling system that includes a fluid pump, as described above in relation to FIG. 7 and FIG. 8. The fluid pump is configured to pump the coolant. Petition 870250089714, dated 02 / 10 / 2025, page 27 / 92 20 / 47 generating through the refrigerant lines. Section A 404 also includes a series of fluid lines, as described in relation to FIG. 7 and FIG. 8. In turn, section B 406 is a control section of power cabinet 400, described further below.

[0068] Section A 404 includes a series of modules that can be arranged together. The modules can be physically identical so that one module can be replaced by another and so that the modules can be arranged compactly within Section A 404. The modules can be supplied with switches that alter their functions. However, alternatively, one or more of the modules can be different in order to accommodate different power control functionalities.

[0069] In the example of FIG. 4, Section A 404 includes a first inverter module 408, a second inverter module 410, and a third inverter module 412. Each inverter module is programmed by the switches (or is otherwise configured) to operate as an inverter, as described elsewhere in this document. Together, the inverter modules in Section B 406 can operate as a single inverter in the drive system 222 of FIG. 2. A fourth module, a DC / DC converter module 414, is programmed to convert DC electrical power from one voltage to another, different voltage.

[0070] More or fewer modules can be supplied, and the modules can be programmed to perform different electrical functions. Each module can be easily accessed and serviced by opening a door to the 400 power cabinet. The modules can use the same hardware to facilitate replacement and spare parts inventory. This high-voltage portion of the 400 power cabinet can be locked to prevent unauthorized external access.

[0071] Section B 406 includes a system controller 416 and field wiring 418, which may also be part of the drive system. Petition 870250089714, dated 02 / 10 / 2025, page 28 / 92 21 / 47 222 shown in FIG. 2. The drive system cabinet provides ease of access and safety. High-voltage areas are isolated and locked from access. Field wiring 418 and other electronic components may be behind hinged cabinet doors that may also be locked. A maintenance interface 420 may be available in section B 406 to allow access to system data logging, trends, and analysis.

[0072] The system controller 416 in section B 406 can send commands to the drive system 222 based on operator input, engine speed, engine temperature, engine communication, transmission communication, wheel speed, transport truck tilt, and / or internal measurement units (IMUs). The IMU 422 is a device that includes a combination of an accelerometer, a compass, and a gyroscope. Communication with the various system components can occur via J1434 / Canbus, high-speed Ethernet, analog signals, or digital signals.

[0073] The 416 system controller in Section B 406 may use one or more of the algorithms and data described above to determine how and when to energize the engine to achieve reduced emissions and fuel use while maximizing battery life. A 420 maintenance interface may be available to allow access to system data logging, trends, and analysis. Wireless network connectivity may be included to enable remote monitoring, configuration, and cloud-based reporting for a fleet of haul trucks.

[0074] Section A 404 and Section B 406 may also include auxiliary components, including an alternator field static exciter (AFSE), grid blower inverter, coolant pump, and high-power field terminals. Section B 406 may also house a main programmable logic controller (PLC) rack, Petition 870250089714, dated 02 / 10 / 2025, page 29 / 92 22 / 47 software and hardware for data logging and low-voltage control fuses and relays. Again, the 420 maintenance interface can be provided on the port of this cabinet section for on-board troubleshooting and data logging. The rear of the 400 power cabinet can be reserved for field connections and terminations.

[0075] The power cabinet 400 can be electrically connected to a truck controller 424. The truck controller 424 can be the truck controller 240 of FIG. 2. Thus, the various components described in relation to the power cabinet 400 can be controlled via the truck controller 424 as described in relation to FIG. 2.

[0076] FIG. 5 shows a module arrangement for adapting a diesel-electric transport truck. Specifically, FIG. 5 shows a dual module arrangement in the form of module grouping 1 500 and module grouping 2 502. Each of the dual modules controls a wheel motor of the two-wheel motor arrangement shown in FIG. 2. In addition, FIG. 5 shows a drive controller module 504 and a truck controller module 506.

[0077] The 1500 module cluster includes DC / DC 1508, which is a single module having a switch arrangement that commands the module to behave as a DC / DC converter. The 1500 module cluster also includes inverter 1510, which is a single module having a switch arrangement that commands the module to behave as an inverter.

[0078] The 2 502 module cluster includes the 2 512 DC / DC, which is a single module having a switch arrangement that commands the module to behave as a DC / DC converter. The 2 502 module cluster also includes the 2 514 inverter, which is a single module having a switch arrangement that commands the module to behave as an inverter. Petition 870250089714, dated 02 / 10 / 2025, page 30 / 92 23 / 47

[0079] The drive controller module 504 may be one or more of the components in Section B 406 shown in FIG. 4. The truck controller module 506 may be the truck controller 240 shown in FIG. 2.

[0080] If the power requirements for the wheel motors exceed the capacity of the module clusters shown in FIG. 5, one or more additional clusters of DC / DC converter modules and inverter modules can be added in parallel to multiply the system capacity without impacting other modules. If the voltage specifications for one or more wheel motors exceed the capacity of any defined clusters, additional dual inverter modules can be added in series to increase the system capacity without impacting other modules. Thus, multiple module clusters can be added in parallel or in series, depending on the voltage and current specifications of a specific haul truck, without impacting other modules or module clusters.

[0081] Furthermore, each module is physically interchangeable with any other module. The function of any given module can be changed by changing a commutator array in the given module.

[0082] Thus, the modular system of one or more modalities allows a basic set of components to be added or removed at any time with minimal changes to other modules or the need to replace existing components. Each module can be split, run in parallel or in series. Several modules of the same type can be added to increase the system's capacity.

[0083] Modules of one or more modes can operate independently of other modules. This arrangement allows for additional modularity. Petition 870250089714, dated 02 / 10 / 2025, page 31 / 92 24 / 47 operation, as the individual modules can be operated as a single group. This arrangement also increases the reliability of the entire system, since the failure of one module does not affect the operation of other modules. Modules can also be swapped between inverters and DC / DC converters to assume a desired functionality as the mission or configuration of the transport truck changes.

[0084] FIG. 6 shows another arrangement of modules. Like FIG. 5, FIG. 6 shows a grouping of module 1 500, a grouping of module 2 502, a drive controller module 504, and a truck controller module 506. However, in FIG. 6, the positions of the inverters and DC / DC converters have been reversed. This arrangement of modules may better suit a transport truck model that is different from the transport truck model for which the module arrangement was generated in FIG. 6. Thus, FIG. 6 shows the versatility of the modular transport truck drive system described in this document.

[0085] Similarly, FIG. 7 shows yet another arrangement of modules. Like FIG. 5 and FIG. 6, FIG. 7 shows a drive controller module 504 and a truck controller module 506. However, for this specific transport truck retrofit, DC / DC converters were not provided as they are unnecessary. Thus, module group 700 includes two inverters, inverter 1 508 and inverter 2 512. Each inverter is connected to a corresponding wheel motor.

[0086] Many other arrangements of modules and module clusters are possible. Thus, one or more modalities are not limited to the examples shown in this document.

[0087] FIGS. 8, 9, 10, 11, 12, 13 and 14 show examples of modules, in various arrangements, for a modular drive system in a transport truck, according to Petition 870250089714, dated 02 / 10 / 2025, page 32 / 92 25 / 47 with one or more modes. Each of the arrangements shown in FIGS. 8 to 14 uses a single type of module, with multiple modules programmed and arranged to perform different functions, as described in relation to FIGS. 2 to 7. Thus, the reference numbers common to FIGS. 8 to 14 refer to similar components with similar functions and definitions.

[0088] Furthermore, two embodiments are shown in FIGS. 8 to 14. The first embodiment is shown in FIGS. 8 to 11. The first embodiment is directed to a group of two power modules (i.e., module 800 and module 802) connected to a control section (i.e., control section 804). The second embodiment is shown in FIGS. 12 to 11. 14. The second modality is directed to two groupings, where each grouping includes four modules (i.e., grouping 1 1200 and grouping 2 1202, where grouping 1 1200 includes module 1 1204, module 2 1206, module 3 1208 and module 4 1210 and, in turn, where grouping 2 1202 includes module 5 1212, module 6 1214, module 7 1216 and module 8 1218). Thus, again, FIGS. 8 to 12 show the versatility of using modules of one or more modalities to establish, at least in part, the drive system of a transport truck.

[0089] Returning to FIG. 8, a top view of a group of four modules and a control section. However, from the top view, only module 800 and module 802 are visible. Module 800 and module 802 can be, for example, the two inverters shown in FIG. 7, or they can be an inverter and a DC / DC converter pair, as shown in FIG. 5 and FIG. 6. The configuration of the electrical function of the modules is based on the selection of a set of switches (see FIG. 9) supplied in each module.

[0090] The modules are connected to a control section 804, which may be Section B 406 shown in FIG. 4. The control section Petition 870250089714, dated 02 / 10 / 2025, page 33 / 92 The 26 / 47 control section 804 can be used to provide auxiliary power to various components of the haul truck (hydraulics, etc.). Thus, the 804 control section can allow an operator to shut off the engine and operate the truck using alternative power sources such as a battery, fuel cell, solar panels, trolley wire, or some other power source.

[0091] Control section 804 may include a bus connection 806 that connects electrically to module 802 and control section 804. Bus connection 806 is connected to an AC bus 808, which in turn is connected to one or more field terminals 810. Control section 804 may also include one or more capacitors, such as capacitor 812. Control section 804 may also include a DC bus 814 to carry a DC current from control section 804 to other electrical components of the transport truck (e.g., a wheel motor).

[0092] FIG. 9 shows a front view of the module group and the control section shown in FIG. 8. Module 800 and module 802 are shown for reference. Also shown for reference is DC bus 814. In addition, the other two modules of the four-module set are visible, specifically module 816 and module 818.

[0093] The four modules can be identical in construction. Thus, each of the modules 800, 802, 816, and 818 can be interchangeable with each other. The function of the modules changes based on the selection of switches 820 shown on each module next to a handle 822 shown on each module. For example, in one configuration, the switches can cause a module to function as an inverter, in a second configuration, the switches can cause a module to function as a rectifier, in a third configuration, the switches can cause Petition 870250089714, dated 02 / 10 / 2025, page 34 / 92 27 / 47 that a module can function as an alternator field static exciter (AFSE), in a fourth configuration, the switches can cause the module to function as a DC / DC converter, in a fifth configuration, the switches can cause the module to function as an AC / AC converter. Other configurations are possible.

[0094] Handles, such as handle 822, can allow easy access for a human maintenance technician. For example, a module to be serviced can be removed from the module group by pulling handle 822 and a replacement module installed in the module group (along with changing the switches to the desired configuration).

[0095] The top view of the module group, as shown in FIG. 9, also shows a field terminal 824. The field terminal 824 allows the module group to be connected to an external electrical system or to some other electrical component on the transport truck.

[0096] The group of modules may be supported by one or more support structures, such as support structure 826 and support structure 828. The support structures may fix the modules or the control section 804 within a power cabinet 404 disposed on a transport truck chassis or some other portion of the transport truck.

[0097] The module group can also be supplied with a refrigerant inlet 830 and a refrigerant outlet 832. Refrigerant from a refrigerant source flows through the refrigerant inlet 830 via refrigerant lines that are arranged around or within the modules. The refrigerant returns through the refrigerant lines and to the refrigerant source via the refrigerant outlet 832. Petition 870250089714, dated 02 / 10 / 2025, page 35 / 92 28 / 47

[0098] FIG. 10 shows a left side view of the module group and control section 804. The term left is used only to distinguish it from the right side view shown in FIG. 11. The views may be reversed in some embodiments, thus left and right do not imply a specific orientation of the modules and control section 804. Module 800, module 802, control section 804, AC bus 808, support structure 826, support structure 828, coolant inlet 830 and coolant outlet 832 are shown for reference.

[0099] In addition, FIG. 10 shows a bus system for each module. Thus, module 800 includes bus system 834 and module 802 includes bus system 836. Bus system 834 and bus system 836 conduct electrical current through the corresponding module and to the AC or DC terminals of control section 804. The function of bus system 836 may depend on the configuration of the modules.

[00100] FIG. 11 shows a right side view of the modules and control section 804. Again, the term right side refers to the fact that FIG. 11 shows an opposite view, with respect to an axis of the modules, to the view shown in FIG. 10. Module 816, module 818, control section 804, AC bus 808, DC bus 814, support structure 826, support structure 828, coolant inlet 830 and bus system 834 are shown for reference.

[00101] Attention is now turned to FIGS. 12 to 14, which show another embodiment of module groups, together with a control section. Each of the modules shown in FIGS. 12 to 14 are identical in manufacture to module 800, module 800, module 816 and module 818 shown in FIGS. 8 to 11. However, in FIGS. 12 to 14, two groups of four modules are arranged in two clusters, cluster 1 1200 and cluster 2 1202. Petition 870250089714, dated 02 / 10 / 2025, page 36 / 92 29 / 47

[00102] Support structure 1204 of group 1 1200 can be connected to support structure 1206 of group 2 1202. Electrically, the two groups can be connected via a DC bus 1208. The refrigerant lines of the two groups can connect at the interface between support structure 1204 and support structure 1206.

[00103] Group 1 1200 includes four modules, including module 1210, module 1212, module 1214, and module 1216. Similarly, group 2 1202 includes four modules, including module 1218, module 1220, module 1222, and module 1224. Again, the switching arrangement of each module alters the electrical function of a given module. In the example in FIG. 12, the two module groups each operate as a particular function. For example, the switches of the modules in group 1 1200 cause the modules within group 1 1200 to operate as a DC / DC converter. Similarly, the switches of the modules in group 2 1202 cause the modules within group 2 1202 to operate as an inverter. Thus, the arrangement of the modules shown in FIG. Figure 12 may be useful for implementing the arrangement of the dual inverter and dual DC / DC converter shown in FIG. 5.

[00104] In general, an inverter can be implemented using three modules. Thus, a grouping of four modules that has an inverter can be an inverter and a DC / DC converter, or it can be an inverter and a braking cutter. A module of four groupings can be a single DC / DC transformer with parallel modules, or it can be a combination of DC / DC transformers and a braking cutter. Other module arrangements are possible.

[00105] FIG. 13 shows a left side view of the two groupings shown in FIG. 12. Similarly, FIG. 14 shows a right side view of the two groupings shown in FIG. 12. Petition 870250089714, dated 02 / 10 / 2025, page 37 / 92 30 / 47 Again, the terms left and right conveniently distinguish the two views and therefore imply only opposite viewpoints of the clusters, with respect to an axis of the clusters. Cluster 1 1200 and cluster 2 1202 are shown in each of FIGS. 13 and 14.

[00106] FIG. 13 shows module 1212 and module 1216 in group 1 1200. FIG. 13 also shows module 1220 and module 1224 in group 2 1202. In addition, the bus systems of each of the modules (e.g., bus system 1304) are visible in the side views of FIG. 13.

[00107] FIG. 14 shows module 1210 and module 1224 in group 1 1200. FIG. 14 also shows module 1218 and module 1222 in group 2 1202. In addition, the bus systems of each of the modules (e.g., bus system 1304) are visible in the side views of FIG. 14.

[00108] FIG. 15 shows an electrical wiring diagram for a transport truck with a modular drive system, according to one or more embodiments. The electrical wiring diagram shown in FIG. 15 can be implemented using an arrangement of the modules shown in FIGS. 8 to 14.

[00109] The electrical wiring diagram in FIG. 15 uses industry-standard symbols for electronic components. Thus, for example, a diode 1500, a transistor 1502, a resistor 1504, an inductor 1506, and a capacitor 1508 are shown by industry-standard symbols for electrical wiring diagrams.

[00110] The boxes, as described below, surround groups of electrical components in FIG. 15. These boxes show the wiring within a module in a group of modules. The wiring within a given box can be arranged by changing the switches on a corresponding module. Certain power supplies or other components Petition 870250089714, dated 02 / 10 / 2025, page 38 / 92 31 / 47 parts of the transport truck are also shown, such as a 1510 engine, 1512 alternator, 1514 first wheel motor and 1514 second wheel motor.

[00111] A first module 1516 (or set of modules) serves as an alternator field static exciter (AFSE). The first module 1516 (or set of modules) is electrically connected to the alternator 1512.

[00112] A second 1518 module (or set of modules) serves as a DC / DC converter that transforms the voltage level of the electrical power flowing from the alternator. The second 1518 module (or set of modules) is electrically connected to a filter (represented by the series of diodes, including diode 1500) and to two batteries in this example.

[00113] A third 1520 module (or set of modules) serves as an auxiliary DC / DC converter. The third 1520 module (or set of modules) is electrically connected to the second 1518 module.

[00114] A fourth 1522 module (or set of modules) serves as a set of cutters and braking resistors. The fourth 1522 module (or set of modules) is electrically connected to the third 1520 module.

[00115] A fifth module 1524 (or set of modules) serves as a set of traction inverters. The fifth module 1524 (or set of modules) is electrically connected to the fourth module 1522 and to the wheel motors (i.e., wheel motor 1514 and wheel motor 1515).

[00116] In addition to the above, the wiring diagram in FIG. 15 includes sections with additional details. For example, section 1526 shows the wiring detail for the third module 1520 (or set of modules) which serves as the auxiliary DC / DC converter. Furthermore, section Petition 870250089714, dated 02 / 10 / 2025, page 39 / 92 32 / 47 Figure 1528 shows the wiring detail of the first module, 1516, which serves as an AFSE.

[00117] FIG. 16 shows a method for adapting a combustion engine vehicle to a vehicle with a modular drive system, according to one or more embodiments. For example, the method in FIG. 16 can be characterized as a method for adapting a vehicle, including a chassis, an engine connected to the chassis, an alternator connected to the engine, a transmission connected to the engine, and a plurality of wheels connected to the chassis. The method shown in FIG. 16 can be implemented using the modules and other components described in relation to FIGS. 2 to 15. The method in FIG. 16 can be used to adapt a combustion engine transport truck into a hybrid transport truck.

[00118] Step 1600 involves removing the transmission. The transmission can be removed by disconnecting the transmission from the haul truck. Removing the transmission may also include removing other components that will no longer be used on the adapted haul truck, such as a drive shaft, differential, etc.

[00119] Step 1602 involves connecting a drive system to the chassis and alternator. Connecting the drive system to the chassis may include installing a power cabinet on the deck of the haul truck. One or more modules may then be connected and inserted into the power cabinet, although some of the one or more modules may be located elsewhere along the haul truck. Connecting the drive system also includes configuration switches on the modules to configure the modules to operate in a pre-determined functionality designed for the truck being retrofitted.

[00120] The drive system connection also includes connecting the modules to other electrical systems of the transport truck. Petition 870250089714, dated 02 / 10 / 2025, page 40 / 92 33 / 47 transport via wires or other components that connect to the appropriate modules in the transport truck. For example, modules configured as inverters can be electrically connected to the wheel motors of the transport truck. Additionally, modules configured as DC / DC converters can be electrically connected to the output of another module configured as an AFSE. In turn, the AFSE can be connected to the truck's alternator.

[00121] Each module can be directly connected to at least one other module. However, as indicated above, some or all modules do not need to be connected to each other. Each module can be interchangeable with another module. Each module includes one or more switches to control an operating mode of each module. One or more switches in each module are configured to control an electrical interface between the drive system and the vehicle's electrical components, including at least the wheel motors of the transport truck.

[00122] Step 1604 involves connecting a set of wheel motors to the wheels and drive system. Each wheel can be connected to one motor. However, particularly when multiple wheels operate in tandem, one motor can be connected to multiple wheels. In some cases, multiple motors can be connected to a single wheel.

[00123] The connection of the wheel motor assembly to the drive system can be achieved by electrically connecting each of the wheels to one or more modules in the drive system. For example, one of the motors can be connected to one or more modules configured to operate as an inverter. The electrical connection can be made, for example, by a wire running from the wheel motor to a Petition 870250089714, dated 02 / 10 / 2025, page 41 / 92 34 / 47 connection section of a set of modules and, from there, to the module configured to operate as an inverter.

[00124] In one embodiment, the method in FIG. 16 may end after step 1604. However, the method may also continue.

[00125] For example, step 1606 may include the installation of a battery connected to the drive system. The battery may be connected to the drive system by connecting the battery to the connection section of a module or a set of modules. For example, the battery may be connected to a module configured to operate as a DC / DC converter.

[00126] In another example, step 1608 may include arranging, for each of the wheel motors, two of the modules as a pair of modules. In this case, the first of the pair of modules has a first switching arrangement so that the first of the pair of modules operates as a DC voltage converter. The second of the pair of modules has a second switching arrangement so that the second of the pair of modules operates as a traction inverter.

[00127] Step 1610 involves connecting the first of the module pair to the battery. Again, the first pair of modules can be connected to the battery via a connection section of the first pair of modules.

[00128] Step 1612 involves connecting the second of the module pair to one of the wheel motors. Again, the second pair of modules can be connected to the wheel motors via a connection section of the second pair of modules.

[00129] The method in FIG. 16 can be varied. More or fewer steps can be added, or the steps can be performed in a different order.

[00130] For example, a specific implementation of the adaptation method of FIG. 16 is now presented. The example is in the con Petition 870250089714, dated 02 / 10 / 2025, page 42 / 92 35 / 47 text of a transport truck that initially uses only a diesel engine as a power source to drive the wheels of the transport truck.

[00131] The old traction and control system of the existing truck is removed and replaced with new components. Thus, for example, the drive cabinets, some operator controls, the dashboard displays, the dynamic braking module, possibly the rectifier, possibly the alternator, and possibly the traction motors are replaced.

[00132] The multi-source power drive system is manufactured so that inverters, alternator field controllers, and DC / DC converters can be placed together as multiple units or in combination with other components without a complete system redesign. Each item can be placed in series or parallel, depending on the power needs of the specific truck system. The replacement kit is designed so that additional space can be obtained by connecting a standard volume of space to house the components. The interface between the components is designed so that any individual component can be added as a single item and fit into a predefined space without having to manufacture each variant individually. This modularity allows high flexibility in which drive parts are used for each truck application and facilitates manufacturing.

[00133] The multi-source retrofit power system can be extended with autonomous features. For example, the multi-source power system can include technologies such as object detection, braking assistance, driver alert assistance, operation using a centralized control center, or fully autonomous operation. With lower capacity, but easier to power entirely by battery, trucks can be retrofitted or Petition 870250089714, dated 02 / 10 / 2025, page 43 / 92 36 / 47 built using one or more methods.

[00134] One or more embodiments also provide wheeled trucks that are powered by motors embedded in the wheels containing integrated drive packs. Other variations are possible.

[00135] The following additional example is provided and should not be considered as limiting one or more embodiments. A mine operator operates fifty KOMATSU® 930E-2® trucks, twenty-five CATERPILLAR® 793® (CAT 793®) trucks and has a 30% greenhouse gas reduction initiative by 2030. Other equipment manufacturers do not offer emission reduction systems for older generation trucks to meet this timeframe. The current solution would be to scrap the twenty-five CAT 793® trucks and the fifty KOMATSU 930E-2® trucks and purchase 75 new KOMATSU 930E-5® trucks with some type of emission reduction system from other equipment manufacturers. If other trucks from the manufacturer are subsequently added to the fleet at another location, they may not utilize the same emission reduction system and would be incompatible.

[00136] The multi-source energy system of one or more modes allows the mine operator to use the systems and components of FIG. 1 to FIG. 15 and the method of FIG. 16 to upgrade KOMATSU 930E-2® and CAT 793® trucks with emission reduction technology for less than the cost of replacement trucks, while allowing the mine operator to claim greenhouse gas reductions by reusing materials in their existing trucks. The mine operator would have a standardized system across all their trucks that facilitates spare parts, training, maintenance, and supports the same emission reduction technologies. Petition 870250089714, dated 02 / 10 / 2025, page 44 / 92 37 / 47

[00137] Any subsequent trucks added to the fleet can be retrofitted with the same or a similar system to allow compatibility with existing emissions reduction technologies. The ability to apply the retrofit kit of one or more modes to transport trucks acquired in the future is possible due to the modular and flexible design of the retrofit system.

[00138] For example, the CAT 793® retrofit can use a single inverter, a single motor, no alternator, no grid resistor, and a battery. Unnecessary sections of the standard drive enclosure can be removed without any redesign, leaving a smaller system footprint and lower cost. Flexible system controller AE / S allows modules to be added to interface with the CAT® transmission and motor without major changes to the controller.

[00139] In the specific, non-limiting example, the KOMATSU 930E® requires two inverters, an alternator field controller, a mains resistor, a mains resistor blower inverter, and no battery. Flexible system controller AE / S allows modules to be added to interface with the KOMATSU® engine, alternator, and operator controls. The extra drive enclosure sections required for the KOMATSU 930E®, compared to the CAT 793®, are added without any redesign in order to provide the extra features of the KOMATSU 930E®.

[00140] In one embodiment, a battery can be used to reduce emissions on the KOMATSU 930E®. The battery can be added along with a section of the DC / DC cabinet, without replacing any other section of the drive system. As battery technology matures to the point where one or more batteries can adequately power the entire truck, the retrofit kit in one or more embodiments allows the engine field controller, alternator, and alternator sections of the drive system to be retrofitted. Petition 870250089714, dated 02 / 10 / 2025, page 45 / 92 38 / 47 removed from the KOMATSU 930E® without the need for any new equipment or redesign. The system controller is reconfigured to control battery and DC / DC power flow without hardware changes. The glass panel displays are reconfigured to show the status of the new components. The engine, alternator, and support systems can then be completely removed from the KOMATSU 930E® without impacting the drive system or requiring any new equipment.

[00141] In one embodiment, a hydrogen fuel cell can be used to reduce emissions in the KOMATSU 930E®. The fuel cell can be added along with a DC / DC enclosure section and a battery, without replacing any other drive system section. The retrofit kit in one or more embodiments allows the engine field controller, alternator, and drive system alternator sections to be removed from the KOMATSU 930E® without the need for any new equipment or redesign. The system controller is reconfigured to control the power flow from the fuel cell, DC / DC, and battery without hardware changes. The glass panel displays are reconfigured to show the status of the new components. The engine, alternator, and support systems can then be completely removed from the KOMATSU 930E® without impacting the drive system or requiring any new equipment.

[00142] Although the various steps in the flowchart of FIG. 16 are presented and described sequentially, at least some of the steps can be performed in different orders, can be combined or omitted, and some of the steps can be performed in parallel. In addition, the steps can be performed actively or passively.

[00143] FIG. 17 shows a device with a management system Petition 870250089714, dated 02 / 10 / 2025, page 46 / 92 39 / 47 energy storage using one or more modules, as described in this document, according to one or more embodiments. The device 1700 shown in FIG. 17 may be, for example, the transport truck 200 shown in FIG. 2. However, the device 1700 may be other types of devices that use electrical energy. For example, the device 1700 may be a building, a cart (other than a truck), a train, a backhoe or other construction equipment or other types of devices that use electrical energy or contain or are connected to devices that use electrical energy. Thus, the use of the modules and module clusters described in this document is not limited to trucks and, in particular, is not limited to transport trucks.

[00144] Device 1700 includes a managed device 1702. The managed device 1702 is a machine or other electrical component that consumes transformed electrical energy received from a power management system 1704, described below. The managed device 1702 can be one or more managed devices. Thus, the managed device 1702 can include motors, computing systems, robots, propulsion systems, electrical networks, etc. In the example of FIG. 2, the managed device 1702 can be, for example, the right wheel motor 214 and the left wheel motor 216.

[00145] Device 1700 includes a power management system 1704 configured to transform the electrical energy received from the power junction 1706 or the power source 1708. The power management system 1704 is one or more modules or groupings of modules, as described in relation to FIG. 5 to FIG. 14 and thus can be characterized in an example as the electrical wiring diagram of FIG. 15. For example, the drive system 222 of FIG. 2 can be more generally described as the power management system 1704 in FIG. 17. The switches of one or more Petition 870250089714, dated 02 / 10 / 2025, page 47 / 92 The 40 / 47 modules that make up the 1704 power management system define the individual electrical functions of the modules. Thus, the switches of the individual modules can be configured to control an electrical interface between the power management system (as a whole) and the managed device 1702. The electrical interface is one or more power transformation functions of the 1704 power management system.

[00146] Device 1700 may also include a power junction 1706. A power junction 1706 consists of electrical connections (cables, wires, boards, etc.) arranged to receive power from a power source 1708. The power junction 1706 is configured to receive electrical power from the power source 1708 and transmit that electrical power to the power management system 1704.

[00147] The power source 1708 is a source of electrical energy that, as described above, may or may not be part of the device 1700. The power source 1708 may be one or more motors, batteries, fuel cells, solar cells, or other sources of electrical energy.

[00148] Thus, as shown in FIG. 17, the modules, module groupings, and examples of module arrangements and module grouping arrangements described in this document are not limited to use in the drive system of a haul truck, as shown, for example, in FIG. 2. For example, a group of modules or sets of modules arranged as an inverter and DC / DC converter (i.e., the power management system 1704) can be used to manage the electrical power transmitted to a managed device within or connected to a building, a cart (other than a truck), a train, a backhoe, or other construction equipment. Similarly, in an example where the device 1700 is a watercraft, such as a cargo ship Petition 870250089714, dated 02 / 10 / 2025, page 48 / 92 41 / 47 ga, the 1704 power management system may be an arrangement of modules including an inverter, a DC / DC converter and an AFSE or some other arrangement of modules. In this case, the managed device (managed device 1702) of the cargo ship may be one or more motors or other electrical devices within the ship, such as motors, propellers, cranes, etc. Other examples of devices, managed devices and arranged module power management systems are also contemplated.

[00149] A summary of one or more embodiments is now presented. From the above, the drive system of one or more embodiments includes a design modularity that is unique in that the design can handle the large amount of energy that the haul truck drive train uses to transport large loads (compared to smaller trucks). The one or more embodiments system is also designed to minimize structural changes to the haul truck when retrofitted to an existing haul truck, to operate continuously in adverse conditions, to be serviced in the field for minimal downtime, and to provide compatibility with trucks of various manufacturers and sizes.

[00150] The system includes components used to provide a drop-in work solution for haul trucks. Such components include a liquid cooling thermal management system and a reconfigurable system controller to control the flow of energy between various emissions control items, truck power sources, and the drive system. Touchscreen operator displays may be included that can be used to reconfigure the system when system components are added or removed during a haul truck retrofit. Petition 870250089714, dated 02 / 10 / 2025, page 49 / 92 42 / 47

[00151] The multi-source retrofit power system includes one or more combinations of high-power motor drive(s), a DC / DC converter, an alternator field exciter, an alternator, traction motors, a grid blower inverter, a dynamic braking module with blower, a system controller, operator controls, and a glass touchscreen control panel. The power electronics modules used in the inverter and DC / DC are modular and can be configured in various ways based on design parameters for a higher expected peak current load or a higher expected peak voltage load.

[00152] The system controller is used to send commands to the drive system based on operator input, engine speed, engine temperature, engine communication, transmission communication, wheel speed, truck tilt, and / or internal measurement units (IMUs). An IMU is a device that includes a combination of an accelerometer, a compass, and a gyroscope. The system controller also sends commands to the engine based on operator input and displays system status to the operator using touch-sensitive glass screens. Communication with the various system components occurs via J1939 / Canbus, high-speed Ethernet, analog signals, or digital signals. The modularity of the drive system can be extended to the system controller, allowing flexible inputs and outputs to match the varying control interfaces on different manufacturer trucks.The system controller uses one or more algorithms to control the flow of energy between the various emission control items, truck power sources, and the drive system.

[00153] A drive system enclosure arranged in a Petition 870250089714, dated 02 / 10 / 2025, pp. 50 / 92 The 43 / 47 human-reachable area of ​​the haul truck can provide ease of access, relative to existing haul truck access, and security, relative to existing haul truck systems. For example, high-voltage areas can be isolated and blocked from access. Field wiring and electronic components can be behind hinged cabinet doors that can also be locked. A maintenance interface can be available in the system controller section to allow access to data logging, trends, and system analysis. Wireless network connectivity can be included to allow remote monitoring, configuration, and cloud-based reporting for a fleet of haul trucks.

[00154] A useful feature of one or more modalities is that the multi-source power system can be an adaptation kit for other trucks from the equipment manufacturer, whether diesel-electric or diesel-mechanical. Many fleets have older trucks that are mechanically sound but are powered by obsolete and unsupported drive systems. These operators may also have older trucks that are powered by older drive systems that do not support newer emissions reduction technologies.

[00155] The multi-mode system allows end-users of transport trucks to upgrade their drive systems to newer technologies without requiring the financial investment and carbon footprint associated with completely new trucks. The upgrade involves simply replacing the existing drive housing, grid resistor, and panel gauges with the multi-source retrofit system described in this document. This retrofit kit can provide a single base system for all trucks in the fleet. A single base system simplifies inventory. Petition 870250089714, dated 02 / 10 / 2025, pp. 51 / 92 44 / 47 spare parts, training, maintenance, and enables future emissions control systems that can be implemented across the fleet.

[00156] The main mechanical components of the truck can be retained and adapted with the propulsion components of one or more models. This design feature of one or more models allows the large, manufacturing-intensive components of a truck to be reused.

[00157] The system can use hardware, software, and driver interfaces that allow an entire fleet to have the same maintenance, operator interface, and spare parts, regardless of the type of truck or other equipment manufacturer. The system can integrate standard components with kit components of one or more modalities in order to create a base system that can be modularly assembled into a system relevant to a specific truck haulage adaptation operation.

[00158] Although the figures show one component configuration, other configurations can be used without departing from the scope of one or more modalities. For example, several components can be combined to create a single component. As another example, the functionality performed by a single component can be performed by two or more components.

[00159] The term approximately, when used in relation to a measurable physical property, refers to an engineering tolerance anticipated or determined by an engineer or manufacturing technician skilled in the art. The exact quantified degree of an engineering tolerance depends on the product being produced and the technical property being measured. For example, two angles may be approximately congruent if the values ​​of the two angles are within a predetermined first range of Petition 870250089714, dated 02 / 10 / 2025, pp. 52 / 92 45 / 47 angles for one modality, but they can also be approximately congruent if the values ​​of the two angles are within a second predetermined range of angles for another modality. One skilled in the art is able to assess what constitutes an acceptable engineering tolerance for a specific product and is therefore able to evaluate how to determine the measurement variance contemplated by the term approximately.

[00160] As used in this document, the term connected to has at least two meanings unless otherwise indicated. In a first meaning, connected to means that component A was, at least at some point, separate from component B, but was subsequently joined to component B in a fixed or removablely attached arrangement. In a second meaning, connected to means that component A could have been integrally formed with component B. Thus, for example, a pan bottom is connected to a pan wall. The term connected to can be interpreted as the bottom and wall being separate components that are fitted together, welded, or otherwise fixedly or removablely attached to each other. However, the bottom and wall can be considered connected when formed contiguously together as a monoblock body.

[00161] Furthermore, the term directly connected to means that component A and component B are connected immediately adjacent to each other. For example, component A and component B may share a common point of contact in at least one area of ​​both components. However, the common point of contact may be a connector (e.g., a screw, a bolt, etc.), in which case it is possible for component A to be directly connected to component B without direct contact between the surfaces of component A and component B. However, in Petition 870250089714, dated 02 / 10 / 2025, pp. 53 / 92 46 / 47 In any case, if component A and component B are directly connected to each other, then no intervening part, except possibly a connector, exists between component A and component B.

[00162] The figures show embodiments that are consistent with the disclosure. The embodiments in the figures may be combined and may include or be included within the features and embodiments described in the other figures of the application. The features and elements in the figures are, individually and as a combination, improvements in hybrid haul truck technology. The various elements, systems, components and steps shown in the figures may be omitted, repeated, combined and / or altered as shown in the figures. Accordingly, the scope of this disclosure should not be considered limited to the specific arrangements shown in the figures.

[00163] In the request, ordinal numbers (e.g., first, second, third, etc.) may be used as an adjective for an element (i.e., any noun in the request). The use of ordinal numbers is not to imply or create any particular ordering of the elements nor to limit any element to being only a single element, unless expressly disclosed, such as by the use of the terms before, after, single, and other terminology. Instead, the use of ordinal numbers is to distinguish between the elements. As an example, a first element is distinct from a second element, and the first element may encompass more than one element and succeed (or precede) the second element in an ordering of elements.

[00164] Furthermore, unless expressly indicated otherwise, the word "or" is an inclusive "or" and, as such, includes "and". Additionally, items joined by "or" may include any combination. Petition 870250089714, dated 02 / 10 / 2025, pp. 54 / 92 47 / 47 of the items with any number of each item, unless expressly indicated otherwise.

[00165] In the description above, several specific details are set forth in order to provide a more complete understanding of one or more modalities. However, it will be evident to those skilled in the art that one or more modalities can be practiced without these specific details. In other cases, well-known features have not been described in detail to avoid unnecessarily complicating the description. Furthermore, other modalities not explicitly described above may be conceived that do not depart from the scope of one or more modalities as disclosed in this document. Therefore, the scope of one or more modalities shall be limited only by the appended claims. Petition 870250089714, dated 02 / 10 / 2025, pp. 55 / 92

Claims

1 / 7 CLAIMS 1. Device, characterized in that it comprises: a junction configured to receive electrical energy from a power source; a power management system connected to the junction, the power management system configured to transform the electrical energy into transformed electrical energy; and a managed device connected to the power management system, wherein the managed device is configured to consume the transformed electrical energy;wherein the energy management system comprises a plurality of modules, wherein each of the plurality of modules is directly connected to at least one other module of the plurality of modules, wherein each of the plurality of modules is interchangeable with another of the plurality of modules, wherein each of the plurality of modules includes one or more switches to control an operating mode of each of the plurality of modules, and wherein one or more switches of each of the plurality of modules are configured to control an electrical interface between the energy management system and a plurality of electrical components of the device, the plurality of electrical components including at least the managed device.

2. Device according to claim 1, characterized in that the power management system comprises a drive system and wherein the device comprises a vehicle comprising: a chassis; Petition 870250089714, dated 10 / 02 / 2025, page 56 / 92 2 / 7 an engine connected to the chassis; an alternator connected to the engine and the drive system; a plurality of wheel motors connected to the drive system, wherein the managed device comprises the plurality of wheel motors; and a plurality of wheels connected to the plurality of wheel motors.

3. Device according to claim 1, characterized in that the plurality of modules is arranged in a plurality of module groupings, wherein each of the plurality of module groupings comprises at least two of the plurality of modules.

4. Device according to claim 1, characterized in that each of the plurality of modules is identical to others in the plurality of modules and in that an arrangement of one or more switches of each of the plurality of modules changes an electrical function of each of the plurality of modules.

5. Device according to claim 2, characterized in that the drive system further comprises: a rectifier connected to a plurality of modules; a grid braking resistor connected to a plurality of modules; and a blower connected to the grid braking resistor.

6. Device according to claim 2, characterized in that at least one of the plurality of modules comprises an inverter and in which the drive system further comprises: a static field exciter of the alternator connected to the inverter and to the alternator, wherein the static field exciter of the alternator is configured to control the electrical energy flowing to the inverter from the alternator.

7. Device according to claim 2, characterized in that at least one of the plurality of modules comprises a grid fan inverter and wherein the drive system comprises: a blower connected to the grid blower inverter; and a plurality of grid braking resistors connected to the blower.

8. Device according to claim 2, characterized in that it further comprises: a refrigerant source connected to the chassis; and a refrigerant pump connected to the refrigerant source and to a plurality of modules, wherein the refrigerant pump is configured to pump refrigerant from the refrigerant source to the plurality of modules.

9. Device according to claim 2, characterized in that it further comprises: a battery connected to the chassis, wherein a first module of the plurality of modules has a first switching arrangement such that the first module functions as a DC voltage converter, the first module connected to the battery, and wherein a second module of the plurality of modules has a second switching arrangement such that the second module functions as a traction inverter, the second module connected to the first module and to a wheel motor of the plurality of wheel motors.

10. Device according to claim 9, characterized in that it further comprises: Petition 870250089714, dated 02 / 10 / 2025, page 58 / 92 4 / 7 a braking resistor connected to the second module.

11. Device according to claim 9, characterized in that it further comprises: a second battery connected to the chassis, wherein a third module of the plurality of modules has the first switching arrangement such that the third module functions as a second DC voltage converter, the third module connected to the second battery, wherein a fourth module of the plurality of modules has the second switching arrangement such that the fourth module functions as a second traction inverter, the fourth module connected to the third module and to a second wheel motor of the plurality of wheel motors, and wherein the fourth module is further connected to the second module.

12. Device according to claim 11, characterized in that it further comprises: a second braking resistor connected to the fourth module.

13. Device according to claim 11, characterized in that it further comprises: a pantograph carriage connected to the chassis, wherein a fifth module of the plurality of modules has the first switching arrangement such that the fifth module functions as a third DC voltage converter, wherein the fifth module is connected to the pantograph carriage, the second module and the fourth module.

14. Device, according to claim 2, characterized in that the plurality of modules comprises: a first module having a first configuration of Petition 870250089714, dated 02 / 10 / 2025, page.59 / 92 5 / 7 switches so that the first module functions as a first DC voltage converter module; a second module having the first switch configuration so that the second module functions as a second DC voltage converter module; a third module having a second switch configuration so that the third module functions as a first inverter module; and a fourth module having the second switch configuration so that the fourth module functions as a second inverter module, wherein the first module and the second module are arranged as a first pair, wherein the third module and the second module are arranged as a second pair, wherein the first module is connected to the third module and the second module is connected to the fourth module.

15. Device according to claim 14, characterized in that the first module and the third module are connected to a controller.

16. Device according to claim 14, characterized in that the second module and the fourth module are connected to a controller.

17. Device according to claim 14, characterized in that the first module and the second module are configured as traction inverters and in that the traction inverters are connected to a plurality of wheel motors and to a plurality of braking resistors that are connected to a plurality of wheel motors.

18. Device, according to claim 1, characterized by the fact that the plurality of modules comprises: a first module having a first configuration of switches so that the first module functions as a first inverter, the first module connected to a controller; and a second module having the first configuration of switches so that the second module functions as a second inverter, the second module connected to the controller.

19. Vehicle, as defined in claim 2, characterized in that the vehicle comprises a transport truck.

20. A method for adapting a vehicle, characterized in that it comprises a chassis, an engine connected to the chassis, an alternator connected to the engine, a transmission connected to the engine, and a plurality of wheels connected to the chassis, the method comprising: removing the transmission; connecting a drive system to the chassis and the alternator; and connecting a plurality of wheel motors to the plurality of wheels and the drive system, wherein the drive system comprises: a plurality of modules, wherein each of the plurality of modules is directly connected to at least one other module of the plurality of modules, wherein each of the plurality of modules is interchangeable with another of the plurality of modules, wherein each of the plurality of modules includes one or more switches to control a mode of operation of each of the plurality of modules, and wherein one or more switches of each of the plurality of modules... (Petition 870250089714, dated 02 / 10 / 2025, p.)61 / 92 7 / 7 of the modules are configured to control an electrical interface between the drive system and a plurality of electrical components of the vehicle, the plurality of electrical components including at least the plurality of wheel motors.

21. Method according to claim 20, characterized in that it further comprises: installing a battery connected to the drive system.

22. Method according to claim 21, characterized in that it further comprises: arranging, for each of the plurality of wheel motors, two of the plurality of modules as a pair of modules, wherein the first of the pair of modules comprises a first switching arrangement such that the first of the pair of modules comprises a DC voltage converter and wherein the second of the pair of modules comprises a second switching arrangement such that the second of the pair of modules comprises a traction inverter; connecting the first of the pair of modules to the battery; and connecting the second of the pair of modules to one of the plurality of wheel motors. Petition 870250089714, dated 10 / 02 / 2025, pp. 62 / 92

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