Hybrid Mechanical Transport Truck System

Description

Hybrid Mechanical Transport Truck 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 24 hours a day. 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 vehicle. The vehicle includes a chassis and an engine connected to the chassis. The vehicle also Petition 870250089877, dated 02 / 10 / 2025, page 10 / 87 2 / 45 includes a torque converter directly connected to the engine. The vehicle also includes an electric motor that has a first side and a second side directly connected to the torque converter, opposite the engine. The electric motor further includes a rotor that has an annular shaft cavity. The electric motor also includes a first diameter equal to or smaller than a second diameter of the torque converter. The electric motor is connected to the torque converter through the annular shaft cavity. The vehicle also includes a drive shaft directly connected to the electric motor, opposite the torque converter. The drive shaft is operationally disposed in the annular shaft cavity. The vehicle also includes a transmission connected to the drive shaft. The vehicle also includes a differential connected to the transmission. The vehicle also includes wheels connected to the differential.

[005] One or more embodiments provide for another vehicle. The vehicle includes a chassis and an engine connected to the chassis. The vehicle also includes a torque converter directly connected to the engine. The vehicle also includes a drive shaft directly connected to the torque converter. The vehicle also includes an electric motor connected to the drive shaft, opposite the torque converter. The electric motor further includes a rotor that has an annular shaft cavity. The electric motor further includes a first diameter equal to or smaller than a second diameter of the torque converter. The electric motor is connected to the drive shaft through the annular shaft cavity. The vehicle also includes a transmission connected to the electric motor. The vehicle also includes a differential connected to the transmission. The vehicle also includes wheels connected to the differential.

[006] One or more embodiments provide a method of adapting a haul truck including a chassis, an engine connected to the chassis, a torque converter connected to the engine, a drive shaft directly connected to the torque converter, Petition 870250089877, dated 02 / 10 / 2025, page 11 / 87 3 / 45 a transmission directly connected to the drive shaft, a differential connected to the transmission, and wheels connected to the differential. The method includes decoupling the drive shaft from the torque converter. The method also includes removing a length of the drive shaft to form a shortened drive shaft. The method also includes connecting an electric motor directly to the torque converter or directly to the transmission. The method also includes connecting the shortened drive shaft to the electric motor so that the torque converter is reconnected to the transmission via the electric motor and the shortened drive shaft.

[007] One or more embodiments also provide a method of operating a haul truck including an engine. The method includes energizing a drive system and the electric motor of the haul truck. The method also includes modifying, by means of a torque converter connected to the engine and directly connected to the electric motor, a torque applied by an engine to the torque converter to generate a modified torque. The method also includes applying, by means of the torque converter, the modified torque to the electric motor. The method also includes rotating, by means of the modified torque, a rotor of the electric motor. The method also includes rotating, with the rotor, a drive shaft connected to the rotor. The method also includes rotating, with the drive shaft, a transmission of the haul truck. The method also includes rotating, with the transmission, a differential of the haul truck. The method also includes propelling, with the differential, the wheels of the haul truck.

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

[009] FIG. 1 shows a transport truck, according to one or more modes. Petition 870250089877, dated 02 / 10 / 2025, page 12 / 87 4 / 45

[0010] FIG. 2 shows a block diagram of a transport truck modified as a hybrid transport truck, according to one or more modes.

[0011] FIGS. 3, 4, 5 and 6 show different views of the transport truck shown in FIG. 1, according to one or more modes.

[0012] FIG. 7 and FIG. 8 show different views of the electric motor installed on the transport truck of FIG. 2 or on the transport truck, as shown in the views of FIG. 3, FIG. 4 and FIG. 6, according to one or more embodiments.

[0013] FIG. 9 shows a power cabinet for use in the hybrid transport truck shown from FIG. 2 to FIG. 6, according to one or more embodiments.

[0014] FIG. 10 shows a flowchart for energy management during the operation of a hybrid transport truck, according to one or more modes.

[0015] FIG. 11 shows a flowchart of a method for adapting a transport truck, according to one or more modes.

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

[0017] Generally, the embodiments are directed to a hybrid haul truck that combines a combustion engine and an electric motor as a drive system for the haul truck. One or more embodiments also include methods and devices for adapting many different types of haul trucks to operate as hybrid haul trucks.

[0018] Because haul trucks are very expensive (millions of dollars for each haul truck), replacing a Petition 870250089877, dated 02 / 10 / 2025, page 13 / 87 Replacing a fleet of 5 / 45 of a traditional combustion engine transport truck fleet with a fleet of new hybrid engine transport trucks can be prohibitively expensive. However, retrofitting an existing combustion engine transport truck to use a hybrid or fully electric drive system has not been practical or economical.

[0019] Adaptation has not been practical because the unique design of haul trucks (long drive axles (compared to automobiles), different drive axle and transmission locations (compared to smaller trucks), etc.) presents technical challenges for adaptation. There are additional technical challenges to adaptation. 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 electric motors.

[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 approaches address the technical challenges involved in adapting a truck economically. Petition 870250089877, dated 02 / 10 / 2025, page 14 / 87 6 / 45 transport to use a hybrid drive system. One or more modalities provide a single-base drive system and a modular power system that can be placed across an entire fleet of existing mixed haul truck models. The electric motor and drive system are specifically designed to handle the large amount of torque that the haul truck drive train uses to haul heavy loads while also being small enough to fit in the available space.

[0022] Due to the transmission architecture of mechanical haul trucks, an electric motor of one or more types can be aligned with the drive shaft to provide torque assistance to the engine. The electric motor is mounted directly on the torque converter on the engine side of the drive shaft or is mounted directly on the transmission on the differential side of the drive shaft. The drive shaft is shortened to accommodate the space occupied by the electric motor. This arrangement allows for a solution without more inconvenient mechanical or operational modifications to the haul truck.

[0023] The electric motor is powered by a drive system and battery. The battery is charged by regenerative braking when the haul truck is going downhill or stopping. Supplemental charging using an external power source is available if the terrain where the haul truck is operating does not have sufficient slope to properly charge the battery.

[0024] Thus, single or multi-mode transport trucks address the challenges described above. For example, single or multi-mode transport trucks have an electrical system designed (as described below) to handle much higher voltages and currents than those used in other applications. Petition 870250089877, dated 02 / 10 / 2025, page 15 / 87 7 / 45 common flanges. The components of one or more models are also designed to minimize the structural modifications applied to a haul truck when adapting an existing haul truck.

[0025] One or more modes allow the electric motor to shift some of the engine load while maintaining reference performance. One or more modes may use the electric motor to vary the load on the engine to optimize engine operating efficiency. One or more modes may use the electric motor to increase haul truck performance by producing more power than the engine alone. One or more modes may use the electric motor to allow the engine to be completely switched off while the haul truck is still operating. Thus, one or more modes reduce fuel consumption and carbon emissions by reducing the amount of time the engine is operational, while still optimizing engine efficiency.

[0026] Attention is now turned to the figures. FIG. 1 shows a transport truck 100, according to one or more embodiments. The transport truck 100 includes a cab 102 in which a human operator may be present during the operation of the transport truck 100.

[0027] Transport truck 100 has a chassis 104, which forms the structure of transport truck 100. Chassis 104 may include more components than just the chassis 104 portion shown in FIG. 1.

[0028] Transport truck 100 also includes a series of wheels, such as wheel 106. The wheels are driven by the transport truck's drive system, as described in relation to FIG. 2 through FIG. 6. Transport truck 100 also includes a Petition 870250089877, dated 02 / 10 / 2025, page 16 / 87 8 / 45 base 108 for transporting loads such as earth, sand, rocks, metals and other types of materials.

[0029] FIG. 4 shows several cutting lines to reference the views shown from FIG. 3 to FIG. 6. Thus, for example, line AA 110 shows the location of a cutting line for section AA in Fig. 3. Similarly, line DD 112 shows the location of a cutting line for section DD in FIG. 5. Likewise, line EE 114 shows the location of a cutting line for section EE in FIG. 6.

[0030] FIG. 2 shows a block diagram of a modified transport truck as a hybrid transport truck, according to one or more embodiments. Transport truck 200 may be a block representation of transport truck 100 shown in FIG. 1.

[0031] The 200 transport truck includes a 202 chassis that forms a structure for the 200 transport truck. Thus, the 202 chassis may include many different components connected directly or indirectly to one another, including panels, crossbeams, grilles, connectors, etc. Some of the components of the 202 chassis are shown in FIG. 1 and FIG. 3 through FIG. 6. However, in general, one or more embodiments contemplate avoiding modification of the 202 chassis as far as possible during a hybrid adaptation procedure. However, modifications to the 202 chassis may be made when adapting certain transport truck models to hybrid technology.

[0032] The 200 transport truck also includes a 204 engine connected to the 202 chassis. The 204 engine may be one or more internal combustion engines, such as one or more diesel engines.

[0033] The 200 transport truck also includes wheels connected to the 202 chassis, connected (indirectly) to the 204 engine via Petition 870250089877, dated 02 / 10 / 2025, page 17 / 87 9 / 45 of the electric motor 222 and other intervening components. Transport trucks generally include four or more wheels. In the example in FIG. 2, transport truck 200 includes right front wheel 206, left front wheel 208, right rear wheels 210 (two wheels operating in tandem) and left rear wheels 212 (two wheels operating in tandem).

[0034] The 200 transport truck also includes a 214 torque converter. The 214 torque converter is a device, usually implemented as a type of fluid coupling, that transfers rotational energy from a prime mover, such as the 204 internal combustion engine, to a rotary driven load. In unmodified transport trucks, the 214 torque converter is connected directly to the 216 drive shaft. However, as explained below, in one or more embodiments, the 216 drive shaft is directly connected to the 214 torque converter or to the 204 engine on the side of the 204 engine to which the 214 torque converter is connected.

[0035] The drive shaft 216 is connected to a transmission 218. The transmission 218 is an assembly of gears and other components that transforms the speed or direction of a machine. The transmission 218 can adjust the gear ratio between the motor and the differential so that the motor remains in a reduced speed range, regardless of the vehicle's final speed.

[0036] Transmission 218 is connected to differential 220. Differential 220 is an assembly of gears and other components that transmits rotational power from transmission 218 to the wheels. Differential 220 can allow the wheels to rotate at different speeds when turning. For example, drive shaft 216 can rotate around an axis parallel to a length of drive shaft. Petition 870250089877, dated 02 / 10 / 2025, page 18 / 87 10 / 45 ment 216. The differential changes the direction of rotation of the drive shaft 216 to a direction of rotation perpendicular to the length of the drive shaft 216. In this way, the direction of rotation in the differential 220 can be perpendicular to the length of the drive shaft 216.

[0037] The 200 transport truck also includes an electric motor 222, which can be installed on the 200 transport truck during an adaptation process, as explained below. The electric motor 222 is directly connected to the torque converter 214 or to the motor 204 on the side of the motor 204 to which the torque converter 214 is connected. The electric motor 222 is then connected to the drive shaft 216, which in turn connects to the transmission 218, the differential 220, and the rear wheels. The position of the electric motor 222 may vary, as described further below.

[0038] A useful design aspect of the placement of the electric motor 222 is that the electric motor is secured during high-impact and high-vibration operations while the haul truck 200 is in use. Furthermore, the electric motor 222 fits within an existing space near the torque converter 214 and, consequently, can be sized and dimensioned to be approximately equal to or smaller than the corresponding dimensions of the motor 204. The electric motor 222 is designed for use with the haul truck 200 and, specifically, is designed to be installed in an existing haul truck with a combustion engine drive system (i.e., an existing haul truck with an engine directly connected to a drive shaft, which is directly connected to a transmission, which is directly connected to a differential, which is directly connected to the wheels).

[0039] The 222 electric motor can be an alternating current (AC) electric motor that provides a minimum of 400 kilowatts (kW) of Petition 870250089877, dated 02 / 10 / 2025, page 19 / 87 11 / 45 continuous electrical power. The 222 electric motor can also deliver 800kW peak power at a rotational speed of 1800 revolutions per minute (RPM) to achieve the desired fuel economy.

[0040] In addition, the 222 electric motor can be sealed to prevent the entry of liquid, dust and other contaminants. The undercarriage of a haul truck is a dirty environment with mud, stones and debris that are thrown up and stick to the undercarriage surfaces. Thus, sealing features can be provided to prevent debris from entering the internal parts of the 222 electric motor.

[0041] The electric motor 222 is connected to an inverter 224. The inverter 224 is an electronic device or circuit that changes direct current (DC) to alternating current (AC). The AC current can be a form of electrical current that is used to control the speed and torque of the electric motor 222.

[0042] The 224 inverter can operate in a voltage range from less than 1000 volts (V) to more than 2600V and current from less than 1000 amperes (A) to more than 4000A. The 224 inverter can be used with different motors, electric traction motors and alternators, while also fitting into the available space on the floor of the 200 transport truck.

[0043] Specifically, the 224 inverter may include a set of four liquid-cooled power electronic devices. Three devices may be used as phase legs of the 224 inverter and the fourth device may be used as a braking cutter or DC / DC converter. This grouping may be supported by a laminated AC and DC bus design that allows stacking multiple groupings to form a system.

[0044] The groupings can be combined in parallel to Petition 870250089877, dated 02 / 10 / 2025, page 20 / 87 12 / 45 increases the total maximum current with each set of parallel groups. The groups can also be combined in series to increase the total maximum voltage with each set of series groups. Such an arrangement allows compatibility with different motors and alternators that are designed for different voltages and currents. Thus, for example, the 224 inverter can be customized to match the engineering specifications of an older haul truck and potentially several generations of engineering specifications of many different haul trucks.

[0045] The 224 inverter can be composed of multiple inverters in the form of inverter groups. Each group of inverters can be isolated from other groups of inverters to allow each group of inverters to operate independently in the event that one or more of the inverters do not function within predetermined engineering specifications. This arrangement allows a diesel-electric transport truck to still move slowly in the event that an inverter or the electric motor does not function within predetermined engineering specifications.

[0046] Isolation can extend beyond the inverter 224. DC / DC groups can be isolated from each other to allow the power system to completely disconnect power sources that might be operating outside predetermined engineering tolerances.

[0047] The 224 inverter can be connected to a 226 battery. The 226 battery is one or more batteries that store or discharge electrical energy through the 224 inverter. For example, dual batteries can be used. Each of the dual batteries can be connected to an isolated DC / DC converter and to the 224 inverter, thus providing an independent power system. Petition 870250089877, dated 02 / 10 / 2025, page 21 / 87 13 / 45

[0048] Battery 226 can be charged using motor 204 (using regenerative braking), by a fast charger, or by another compatible haul truck system. Battery 226 can also be used to power other systems in haul truck 200 to allow haul truck 200 to operate without motor 204 running.

[0049] The inverter 224 is connected to a power controller 228. The power controller 228 is composed of electrical and mechanical components that control the distribution of electrical power to other electrical components of the transport truck 200. For example, the power controller 228 can control the amount of power generated or used by the electric motor 222 and thus can control the amount of power applied to the drive shaft 216 through the electric motor 222. The power controller 228 can also control the electrical power to other electrical components in the transport truck 200, such as the battery 226 or various other electrical systems.

[0050] The 228 power controller can be based on a programmable logic controller hardware platform. The platform can be used to control and monitor various functions and systems of the 200 transport truck. Integrated safety can be used to protect against unintentional modifications, while also allowing flexibility in customization depending on customer specifications.

[0051] The 228 power controller may include a variety of components. The 228 power controller may include the programmable logic controller, communication modules and equipment, power supplies and power distribution equipment, diagnostic computing and data logging devices, radio equipment, etc. Petition 870250089877, dated 02 / 10 / 2025, page 22 / 87 14 / 45

[0052] The transport truck 200 also includes an interface 230, which can be connected (at least indirectly) to the power controller 228. The interface 230 includes a monitor (monitor, touch screen, audio device, tactile device, etc.) to display information to a user. The interface 230 also includes one or more user devices (touch screens, speakers, tactile devices, mice, keyboards, etc.), so that an operator can control various functions of the power controller 228.

[0053] One or more embodiments shown in FIG. 2 may vary. The position of motor 222 may be changed to couple to motor 204 instead of to torque converter 214. Alternatively, motor 222 may be directly coupled to transmission 218 instead of to motor 204 or torque converter 214. In the latter case, drive shaft 216 may be connected between motor 222 and torque converter 214.

[0054] Other variations are possible. For example, several motors can be added to increase the power output. One or more motors can be connected to some or all of the wheels of the transport truck 200. The battery 226 can be replaced by hydrogen fuel cells or a cart system, or such alternative energy sources can be added to the transport truck 200 in addition to the battery 226. For example, one or more solar cells can be placed on the transport truck 200 to charge the battery 226 while the transport truck 200 is not in operation or while the motor 204 is inactive.

[0055] FIGS. 3, 4, 5 and 6 show different views of the transport truck shown in FIG. 1, according to one or more embodiments. The components described in relation to FIG. 2 are also shown in the examples from FIG. 3 to FIG. 6. Thus, from FIG. 3 to FIG. 6, the reference numbers are common with FIG. 1 Petition 870250089877, dated 02 / 10 / 2025, p. 23 / 87 15 / 45 refer to similar components with similar descriptions. Similarly, from FIG. 3 to FIG. 6, the reference numbers in common with FIG. 2 refer to similar components with similar descriptions. Similarly, from FIG. 3 to FIG. 6, any reference numbers used in one figure and then repeated in a subsequent figure refer to similar components with similar descriptions.

[0056] FIG. 3 shows the section of the transport truck 100 cut along line AA 110 in FIG. 1. Base 108 is shown for reference. The portion of the transport truck 100 that can be adapted to accommodate a 222 engine is shown in detail section C 300.

[0057] Thus, attention is drawn to FIG. 4, which shows an expanded view of the detail section C 300 in Fig. 3. As can be seen, motor 204 is directly connected to torque converter 214. In turn, electric motor 222 is directly connected to torque converter 214, opposite motor 204.

[0058] The drive shaft 216 is connected to the torque converter 214 via an annular shaft of the electric motor 222 (see FIG. 7 and FIG. 8). Alternatively, the drive shaft 216 is connected to a portion of the annular shaft of the electric motor 222 and the torque converter 214 is connected to an opposite portion of the annular shaft of the electric motor 222.

[0059] The position of the electric motor 222 can be varied. For example, the electric motor 222 can be connected directly to the transmission 218, in which case the drive shaft 216 can connect to the transmission 218 through the electric motor 222. Alternatively, the drive shaft 216 can connect to a first portion of the annular shaft of the electric motor 222. In this case, the transmission 218 can connect to an opposite portion of the annular shaft of the motor. Petition 870250089877, dated 02 / 10 / 2025, page 24 / 87 16 / 45 electric tor 222.

[0060] However, in one or more embodiments, directly connecting the electric motor 222 to the torque converter 214 or to the motor 204 may have additional utility. For example, the electric motor 222 may be higher in the transport truck 100, relative to the ground. The motor 222 may also be more stable when directly connected to the heavier assembly of motor 204 and torque converter 214, relative to transmission 218. The electric motor 222 may also be subject to less shear forces when directly connected to motor 204 or torque converter 214.

[0061] Detail section C 300 shows other components of the transport truck 100 for reference. For example, a central upper frame crossbar 400 is arranged over the drive axle 216, relative to a direction of gravity during normal operation of the transport truck 100. A central lower frame crossbar 402 is arranged under the drive axle 216, relative to the direction of gravity during normal operation of the transport truck 100. A rear axle frame 404 is also shown for reference.

[0062] FIG. 5 shows a section of the transport truck 100 through line DD 112. FIG. 5 shows the location of the first battery 500 and the second battery 502, which together may be battery 226 shown in FIG. 2. FIG. 5 shows a drive cabinet 504 containing parts of the power controller 228 shown in FIG. 2, possibly including the inverter 224.

[0063] FIG. 6 shows a section of the transport truck 100 through line EE 114. In FIG. 6, the position of motor 204, torque converter 214 and motor 222 can be seen. The position of the central crossbar of the upper structure 400 is also shown, along with bar 600 and bar 602 which are part of chassis 202. Petition 870250089877, dated 02 / 10 / 2025, page 25 / 87 17 / 45 Also visible are the drive shaft 216 and the transmission 218.

[0064] FIG. 7 and FIG. 8 show different views of an electric motor 700 installed in the transport truck of FIG. 2 or in the transport truck, as shown in the views of FIG. 3, FIG. 4 and FIG. 6, according to one or more embodiments. Thus, the electric motor 700 can be the electric motor 222 of FIG. 2 or of FIG. 3 to FIG. 6. FIG. 7 and FIG. 8 should be viewed together in the following description.

[0065] The electric motor 700 includes a stator frame 702 that serves as a housing for the electric motor 700. One or more mounting brackets, such as mounting bracket 704, are shown connected to the stator frame 702. The mounting brackets may be sized and dimensioned to allow direct connection of the electric motor 700 to the torque converter or motor. For example, mounting bracket 704 may be connected to the stator frame 702 at one end of the electric motor 700 so that the electric motor 700, when connected to the torque converter or motor, can be directly connected to the torque converter or motor. However, mounting bracket 704 may also be sized and dimensioned to allow the electric motor 700 to be directly connected to the torque converter or motor while still allowing some space between the electric motor 700 and the torque converter or motor.

[0066] The space may allow one or more refrigerant lines, such as a refrigerant supply line 706 and a refrigerant drain line 708, to be connected to the electric motor 700. The refrigerant supply line 706 and the refrigerant drain line 708 may be connected to refrigerant lines, such as the refrigerant line 710 and the refrigerant liquid line 712. The refrigerant line 710 and the refrigerant line 712 Petition 870250089877, dated 02 / 10 / 2025, page 26 / 87 18 / 45 are tubes or other fluid or gas communication channels that allow refrigerant to pass between the refrigerant supply line 706 or the refrigerant drain line 708 and a refrigerant source 714.

[0067] Refrigerant source 714 is connected inside the transport truck (e.g., to the chassis or as part of the power control system). Refrigerant source 714 stores the refrigerant. The refrigerant can be a liquid (e.g., water, antifreeze, or some other liquid) or a gas (e.g., air, a refrigerant gas, etc.).

[0068] During use, liquid coolant can be pumped from coolant source 714, through coolant line 710, and then to motor 700 through coolant supply line 706. The coolant is then circulated within or around motor 700. For example, coolant lines within motor 700 can allow coolant to circulate within motor 700 without the coolant touching the motor's internal components. The coolant then returns through coolant drain line 708 to coolant line 712 and then back to coolant source 714. Optionally, one or both coolant line 710 and coolant line 712 can be connected to an intervening radiator in order to increase heat dissipation from the coolant as the coolant exits electric motor 700.In both cases, the circulation of coolant within or around the 700 motor can help maintain the 700 electric motor within a predetermined temperature range for a selected engineering tolerance.

[0069] The electric motor 700 also includes a rotor 716. The rotor 716 can rotate around a longitudinal axis 718 of the electric motor 700. The rotor 716 can be connected to a drive shaft (for example, the drive shaft 216 of FIG. 2). Thus, when the shaft Petition 870250089877, dated 02 / 10 / 2025, page 27 / 87 The 19 / 45 drive shaft is rotated by the motor, the drive shaft rotates the rotor 716. In turn, the rotation of the rotor 716 rotates electrically conductive bearings inside the electric motor 700 around a hollow magnetic cylinder arranged around the electric motor 700. The electrically conductive bearings can be, for example, made of copper, although other electrically conductive materials can be used. The hollow magnetic cylinder can be, for example, made of iron, although other magnetic metals can be used.

[0070] As a result of the rotation of the bearings around the hollow magnetic cylinder, electricity can be generated by the electric motor or consumed by the electric motor, depending on the direction of rotation of rotor 716. For example, electricity from a battery can be supplied to the electric motor. As a result, rotor 716 rotates in one direction, causing electric motor 700 to apply force to rotor 716 (therefore, any drive shaft within electric motor 700) and thus cause the drive shaft to rotate. Alternatively, the motor can rotate the drive shaft and thus rotate rotor 716 in the opposite direction, causing electric motor 700 to generate electricity. The generated electricity can be stored in the battery. In another alternative, the drive shaft can be decoupled from the motor while the vehicle is in motion.The movement of the vehicle's wheels can then rotate the drive shaft, i.e., rotor 716, to generate electricity within the electric motor 700. In this case, the electric motor 222 applies torque in a direction opposite to the rotation of the electric motor 222, which, in turn, decreases the rotation of the drive shaft 216 and, consequently, decreases the speed of the transport truck.

[0071] An annular cavity 720 is disposed within or through the rotor 716 of the electric motor 700. The annular cavity 720 is dimensioned to allow a truck drive shaft of Petition 870250089877, dated 02 / 10 / 2025, page 28 / 87 20 / 45 transport is connected to the electric motor 700 inside the annular cavity 720. The annular cavity 720 may be a through hole in the rotor 716 or it may be a chamber inside the rotor 716 that is open on at least one side of the electric motor 700.

[0072] In one embodiment, the torque converter or motor is directly connected to a first side 722 of the electric motor 700. In turn, the drive shaft extends out of the annular cavity 720 on a second side 724 of the electric motor 700. However, in another arrangement, the second side 724 of the electric motor 700 may be connected to a transport truck transmission, with the rotor 716 (possibly via a connection within the annular cavity 720) connected to the transmission. In this case, the drive shaft may extend out of the annular cavity 720 on the second side 724 of the electric motor 700.

[0073] The electric motor 700 may also include a seal 726. The seal 726 may take the form of multiple plates, such as the plates shown in FIG. 7 and FIG. 8. However, the plates may be dimensioned, sized and positioned differently from the arrangement of the plates shown in FIG. 7 and FIG. 8. There may be more or fewer plates. The seal 726 may also take the form of a single piece of material extending through one or both of the first side 722 and the second side 724. However, in this latter variation, a hole in the seal 726 will be present to accommodate the annular cavity 720 so that a drive shaft or other component (torque converter, motor or transmission) may also be connected to the electric motor 700.

[0074] The seal, together with the stator structure 702, prevents debris from foreign objects (soil, fluids, rocks, sand, garbage, etc.) from entering the electric motor 700. In this way, the electric motor 700 can continue to operate under adverse conditions. Petition 870250089877, dated 02 / 10 / 2025, page 29 / 87 21 / 45 during the operation of the transport truck. Although the electric motor 700 may cool more slowly by thermal conduction due to the presence of the seal 726, the cooling system (comprising the coolant supply line 706, coolant drain line 708, coolant line 710, coolant line 712 and coolant source 714) can maintain the operating temperature of the electric motor 700 within the desired engineering tolerances.

[0075] Several additional details of the 700 electric motor are now presented. The 700 electric motor can be, in one embodiment, a fully sealed liquid-cooled electric motor with a diameter of 500 millimeters (mm) (relative to the longitudinal axis 718) and a length of 250 mm (relative to the longitudinal axis 718). The 700 electric motor can have a weight of 140 kilograms (kg) and have overall dimensions that fit into an available area next to the torque converter on the underside of the transport truck.

[0076] In an adaptation operation, this area is not intended for an electric motor. Thus, the diameter of the electric motor may be approximately equivalent to (or smaller than) the diameter of the transmission and / or torque converter cover plate. This area may be free of hoses and auxiliary systems. The bolts used to attach the plate to the transmission and / or torque converter may be lengthened to allow the electric motor to couple directly to the transmission and / or torque converter.

[0077] The diameter of the electric motor, at a peak torque of 4244 newton-meters (Nm), typically uses an 80 mm diameter drive shaft. However, the drive shaft handles the combined torque of the motor and the electric motor. Thus, the diameter of the drive shaft can be up to 120 mm using high-strength 4340 steel. This shaft is 25% of the diameter of the electric motor, therefore the internal parts of the motor (bearings, core, etc.) are designed Petition 870250089877, dated 02 / 10 / 2025, page 30 / 87 22 / 45 to compensate for the lost electromagnetic area.

[0078] Part of the trade-off is increasing the pole count to tens of poles (e.g., 40 poles) compared to the four or eight poles typically used in standard electric motors to utilize a permanent magnet rotor, as opposed to the induction rotors typically seen in haul truck electric motors. Additionally, the 700 electric motor uses liquid cooling instead of the air cooling typically seen in haul truck electric motors. Liquid cooling allows for a more compact and fully sealed electric motor for the harsh environment under the haul truck.

[0079] To enable the power and dimensions described above, an exemplary 700 motor included a liquid-cooled permanent magnet rotor with N52UH magnets and 40 poles. The 700 electric motor had a peak power of 800 kilowatts (kW) for over 5 minutes to allow for maximum battery charging during downhill operation. The haul truck motor typically operates in a fixed speed range of 800 RPM to 1800 RPM. This RPM range means the electric motor produced maximum torque in the same range as the motor produces maximum torque, around 1800 RPM. Increasing the pole count (to 40 in this specific example) allowed the electric motor to produce the desired torque at these speeds without incurring large electrical losses that increase temperature and decrease the lifespan of the permanent magnets.Increasing the pole count also meant that the power electronics components controlling the electric motor operated at much higher frequencies than those normally used for these power levels in mining equipment. The power electronics components of the power control system are designed to handle these frequencies with minimal losses. Petition 870250089877, dated 02 / 10 / 2025, page 31 / 87 23 / 45

[0080] FIG. 9 shows a power cabinet for use in the hybrid transport truck shown from FIG. 2 to FIG. 6, according to one or more embodiments. The power cabinet 900 disposed within a welding 902 may be part of the power controller 228 shown in FIG. 2.

[0081] The 900 power cabinet includes two sections with components designed to perform one or more predetermined functions. Section A 904 includes electronic drive components and a liquid cooling system that includes a fluid pump, as described above in relation to FIG. 7 and FIG. 8. Section A 902 also includes a series of fluid lines, as described in relation to FIG. 7 and FIG. 8. In turn, section B 906 is a control section of the 900 power cabinet.

[0082] Section A 904 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 902. 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.

[0083] In the example of FIG. 9, Section A 904 includes a first inverter module 908, a second inverter module 910, and a third inverter module 912. 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 904 can operate as a single inverter in the power controller 228 of FIG. 2. A fourth module, a DC / DC converter module 914, is programmed to convert DC electrical power from one voltage to another, different voltage. Petition 870250089877, dated 02 / 10 / 2025, page 32 / 87 24 / 45

[0084] 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 900 power cabinet. The modules can use the same hardware to facilitate replacement and spare parts inventory. This high-voltage portion of the 900 power cabinet can be locked to prevent unauthorized external access.

[0085] Section B 906 includes a system controller 916 and field wiring 918, which may also be part of the power controller 228 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 and electronic components may be behind hinged cabinet doors that may also be lockable. A maintenance interface 920 may be available in the system controller section to allow access to data logging, trends, and system analysis.

[0086] The system controller in section C 906 can send commands to the drive system based on operator input, electric motor speed, electric motor temperature, motor communication, transmission communication, wheel speed, transport truck tilt, and / or internal measurement units (IMUs). The IMU 922 is a device that includes a combination of an accelerometer, a compass, and a gyroscope. Communication with the various system components can occur via J1939 / Canbus, high-speed Ethernet, analog signals, or digital signals.

[0087] The system controller in Section B 906 may use one or more algorithms and the data described above to determine how and Petition 870250089877, dated 02 / 10 / 2025, page 33 / 87 25 / 45 when energizing the electric motor to achieve reduced emissions and fuel consumption while maximizing battery life. A maintenance interface may be available to allow access to data logging, trends, and system analysis. Wireless network connectivity may be included to enable remote monitoring, configuration, and cloud-based reporting for a fleet of haul trucks.

[0088] Section C 906 may also include auxiliary components, including an alternator field static exciter (AFSE), network blower inverter, coolant pump, and high-power field terminals. Section C 906 may also include haul truck controls and haul truck sensor / instrument interface. The main programmable logic controller (PLC) rack, data logger, and all low-voltage control fuses and relays are housed. A maintenance interface 920 (e.g., interface 230 of FIG. 2) may be provided on the port of this cabinet section for on-board troubleshooting and data logging. The rear of the cabinet may be reserved for field connections and terminations.

[0089] Although FIGS. 1 through 9 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.

[0090] The components described in relation to FIGS. 1 through 9 can be arranged in different configurations. The different configurations provide different transport truck configurations, each considered a variation of the transport truck examples shown in FIGS. 1 through 9. Furthermore, although one or more Petition 870250089877, dated 02 / 10 / 2025, page 34 / 87 26 / 45 configurations are described as a transport truck, one or more configurations may also be useful for manufacturing a hybrid vehicle or for adapting other types of vehicles that include a combustion engine.

[0091] Thus, one or more embodiments provide a vehicle including a chassis, a motor connected to the chassis, and a torque converter directly connected to the motor. An electric motor that has a first side and a second side directly connected to the torque converter, opposite the motor. The electric motor further includes a rotor that has an annular shaft cavity. The electric motor also has a first diameter equal to or smaller than a second diameter of the torque converter, so that the electric motor fits into an existing haul truck. The electric motor is connected to the torque converter through the annular shaft cavity. In addition to the above items, the vehicle also includes a drive shaft directly connected to the electric motor, opposite the torque converter. The drive shaft is operationally disposed in the annular shaft cavity.The vehicle also includes a transmission connected to the drive axle, a differential connected to the transmission, and a set of wheels connected to the differential.

[0092] In the vehicle described above, the electric motor may also include a stator structure arranged around a circumference of the electric motor. In this case, the electric motor also includes a first side facing away from the torque converter and a second side facing the torque converter. The electric motor also includes a mounting bracket directly attached to the stator structure near the second side of the electric motor. The electric motor is connected to the torque converter via the mounting bracket.

[0093] In the vehicle described above, the electric motor may include a first side facing away from the torque converter and a second Petition 870250089877, dated 02 / 10 / 2025, page 35 / 87 27 / 45 side facing the torque converter. The electric motor also includes a seal connected to the first side of the electric motor. The seal at least partially prevents external access to the bearings connected to the rotor inside the electric motor.

[0094] In the vehicle described above, the electric motor may also include a stator structure arranged around a circumference of the electric motor. The electric motor may also be characterized as having a first side facing away from the torque converter and a second side facing the torque converter. A space may be defined between the electric motor and the torque converter. In this case, the electric motor also includes a fluid transmission line connected to the stator structure near the second side of the electric motor. The fluid transmission line is located, at least partially, inside the space. A fluid source may be connected to the fluid transition line and store fluid. A cooling system may be arranged within the stator structure and arranged to distribute the fluid through the cooling system.

[0095] In the vehicle described above, the vehicle may also include an inverter connected to the electric motor. A battery may be connected to the inverter.

[0096] As indicated throughout the descriptive report, the vehicle may be a haul truck. Thus, for example, the chassis of the haul truck may include a pair of longitudinal structural members disposed between a front of the haul truck and a rear of the haul truck. The haul truck may also include a central structural crossmember disposed between the pair of longitudinal structural members. The electric motor may be disposed entirely ahead of the central structural crossmember, relative to the front of the haul truck, and under the central structural crossmember, relative to a direction of gravity. Petition 870250089877, dated 02 / 10 / 2025, page 36 / 87 28 / 45

[0097] In the vehicle described above, a power controller can be connected to the electric motor. The power controller can be configured to control the power coming from or consumed by the electric motor. The power controller may also include a series of inverter modules connected to each other and configured to control a level of power output by the electric motor.

[0098] In the vehicle described above, the vehicle may also include a cab connected to the chassis. A user interface may be disposed within the cab. The user interface may be configured to allow monitoring and configuration of the electric motor or an inverter connected to the electric motor. The user interface may be configured to control a power output from the inverter to the electric motor. For example, the user interface may be configured to allow monitoring and configuration of both the electric motor and the inverter. This configuration may be to disable the hybrid system or to put the hybrid into different driving power modes, such as a higher speed mode instead of the maximum fuel economy mode. Existing haul truck user interfaces, such as the transmission shifter and pedals, may be used to control the power output from the inverter to the electric motor.

[0099] In the vehicle described above, the vehicle may also include a platform connected to the chassis and a power cabinet connected to the platform. An electronic drive and liquid cooling system may be disposed within a first section of the power cabinet, where the liquid cooling system is further connected to the electric motor. Several inverter modules may be connected to each other within a second section of the power cabinet. The inverter modules may be configured to control a power level output by the motor. A controller of Petition 870250089877, dated 02 / 10 / 2025, page 37 / 87 The 29 / 45 system and wiring module can be placed within a third section of the power cabinet. A maintenance interface can be connected to the system controller and wiring module. An access door can be connected to the system controller and wiring module and configured to grant access within the system controller and wiring module. The second section can be adjacent to the first section, and the third section can be adjacent to the second section.

[00100] In another variation, one or more embodiments contemplate a vehicle including a chassis, a motor connected to the chassis, a torque converter directly connected to the motor, and a drive shaft directly connected to the torque converter. An electric motor may be connected to the drive shaft, opposite the torque converter. The electric motor further includes a rotor that has an annular shaft cavity. The electric motor further includes a first diameter equal to or smaller than a second diameter of the torque converter. The electric motor is connected to the drive shaft through the annular shaft cavity. A transmission is connected to the electric motor, and a differential is connected to the transmission. Several wheels may be connected to the differential.

[00101] Again, the vehicle described above may be a transport truck. In this case, the chassis may include a pair of longitudinal structural members disposed between a front of the transport truck and a rear of the transport truck and a central structural crossmember disposed between the pair of longitudinal structural members. In this case, the electric motor may be entirely disposed behind the central structural crossmember, relative to the rear of the transport truck, and under the central structural crossmember, relative to a direction of gravity.

[00102] Other variations are possible. Thus, the examples provided Petition 870250089877, dated 02 / 10 / 2025, page 38 / 87 The above examples and arrangements do not limit other examples or arrangements of the components shown in FIGS. 1 to 9.

[00103] FIG. 10 shows a flowchart for energy management during the operation of a hybrid haul truck, according to one or more modalities. The method of FIG. 10 can be performed using a hybrid haul truck, including a haul truck adapted with a hybrid system as described above. The term system, as described below, refers to the motor, torque converter, drive shaft, power controller (e.g., power controller 228 of FIG. 2), drive electronics components, and other hardware and software components that enable the generation and distribution of power within the haul truck.

[00104] The method begins with the transport truck turned on. Step 1000 includes checking for a hybrid drive mode selection. Specifically, the system checks if the transport truck is operating in a hybrid drive mode.

[00105] Step 1002 involves energizing the drive and electric motor. Energizing the drive and electric motor prepares the drive and electric motor to operate. Energizing may include closing or activating one or more switches that allow power to flow from the battery to the inverter's DC bus. The inverter then uses one or more switches to transform the DC power into AC power to control the electric motor.

[00106] Step 1004 involves determining if the transport truck is moving. If the transport truck is moving (a yes determination in step 1004), then in step 1006, a determination is made whether the throttle is engaged. If the throttle is engaged (a yes determination in step 1006), then step 1008 involves providing positive torque to the electric motor. Two trucks Petition 870250089877, dated 02 / 10 / 2025, page 39 / 87 31 / 45 nhos, then, can be taken simultaneously or sequentially after step 1008.

[00107] Along a path after step 1008, in step 1010, it is determined whether the battery is discharged below a threshold energy level. If not (a no determination in step 1010), then the method returns to the decision in step 1006. If so (a yes determination in step 1010), then step 1012 includes reducing the positive torque to the electric motor. The method then returns to the decision in step 1006.

[00108] Along a second path after step 1008, in step 1012, it is determined whether the transmission is shifting. If the transmission is shifting (a yes determination in step 1012), then step 1014 involves supplying zero torque to the electric motor. For example, the drive shaft can be disengaged from the torque converter or electric motor. Alternatively, the electric motor can be disengaged from the torque converter or electric motor. In both cases, the method returns to step 1012 and continues to repeat. However, if the transmission is not shifting in step 1012 (a no determination in step 1012), then the method returns to step 1008 and positive torque is supplied to the electric motor. In other words, transmission shift monitoring can be in progress while positive torque is supplied to the motor, causing positive torque to be applied to the electric motor.

[00109] Both the first and second paths can be repeated as long as the throttle is engaged in step 1006. However, if the throttle is not engaged (a determination not made in step 1006), then the method proceeds to step 1016. Step 1016 includes determining whether the brake is engaged.

[00110] If the brake is engaged (a yes determination in Petition 870250089877, dated 02 / 10 / 2025, page 40 / 87 32 / 45 stage 1016), then, in stage 1018, the system provides negative torque to the electric motor. As a result, the electric motor rotor rotates in an opposite direction to the direction of rotation of the rotor in stage 1008. The electric motor generates energy and the generated energy can be transferred to the battery.

[00111] A determination is then made in step 1020 whether the battery is charged above a limit value. If so (a yes determination in step 1020), then in step 1022 the system reduces the negative torque to the electric motor. As a result, less energy is transferred to the battery. In one embodiment, the negative torque can be reduced to zero in order to prevent excess energy from being transferred to the battery.

[00112] The method then returns to step 1016 where a new determination is made as to whether the brake is engaged. Similarly, if in step 1020 the battery is not charged above the limit value, then the energy generated by the electric motor is transferred to the battery and subsequently the method returns once again to step 1016.

[00113] If the brake is not engaged (a determination not made in step 1016), then in step 1024 it is determined whether the battery is charged. The decision in step 1024 is also made if the transport truck is not moving (a determination not made in step 1004). If the battery is not charged (a determination not made in step 1024), then in step 1026 the electric motor is engaged to charge the battery. For example, the electric motor may be run to rotate the engine (or to rotate the drive shaft and hence the electric motor), but the drive shaft (or electric motor) may be disengaged from the transmission. As a result, the electric motor rotates and generates electricity which is transmitted to the battery to charge the battery. Once the battery is charged, the electric motor may switch off and the process ends. Petition 870250089877, dated 02 / 10 / 2025, page 41 / 87 33 / 45

[00114] Note that step 1026 may be optional in some cases. For example, it may be determined that the engine can be switched off and the method terminated even if the battery is not charged in step 1024. Such an optional decision may be worthwhile when the haul truck is equipped with solar panels that can charge the battery while the haul truck's engine is not running.

[00115] Going back to step 1024, if the battery is charged (a yes determination in step 1024), then it is determined in step 1028 whether the engine should be turned off. If not (a no determination in step 1028), then the method returns to the decision in step 1004 and the method proceeds from step 1004 as described above. If the engine is turned off (a yes determination in step 1028), then the engine is turned off and the method ends after that.

[00116] The method in FIG. 10 includes several useful aspects. For example, the method in FIG. 10 shuts off the engine when idling and stationary. This procedure reduces fuel consumption and greenhouse gas emissions, because it is common for transport trucks to be idling 30% or more of the time during a typical workday.

[00117] In another example, the method in FIG. 10 provides battery charging during idle time. The motors on the transmission output side cannot charge the battery during idle time. Charging power can be optimized for speed or the lowest amount of fuel consumption. The battery can be charged while idling without increasing the transport truck's fuel consumption compared to normal idle.

[00118] In another example, the method in FIG. 10 means that adapting an existing transport truck can be more efficient. Petition 870250089877, dated 02 / 10 / 2025, page 42 / 87 34 / 45 cyl. For example, the method in FIG. 10 can allow for the minimization of new equipment, such as special modes or pedals to regenerate energy back into the battery.

[00119] In another example, the method in FIG. 10 provides normal operation of the transport truck if the battery charge is low. Thus, the hybrid system transport truck allows the engine to be switched off and the transport truck to operate as a normal combustion engine transport truck.

[00120] In another example, the method in FIG. 10 provides additional braking energy without putting additional wear on the brakes. For example, if the battery charge is low, then the electric motor can be engaged to generate energy for the battery, with the electric motor ultimately being driven by the wheels. The torque produced by the electric motor in the opposite direction of rotation thus forces the wheels to decelerate and therefore slows the vehicle. However, if the battery charge is high, the system can stop regeneration (negative torque) and the haul truck still stops as the haul truck did before an adaptation.

[00121] In another example, the method in FIG. 10 allows the transport truck to move without the engine running. The electric motor alone can be used to force the wheels to move through the drive axle, transmission, and differential when the electric motor is placed after the torque converter.

[00122] The method in FIG. 10 can be read as sub-methods that include different paths along the decision points of the method shown, using components described in relation to FIG. 2. For example, one or more embodiments also provide a method of operating a transport truck including an engine. The method includes energizing a drive system and the electric motor of the transport truck. The method also includes modifying, by a Petition 870250089877, dated 02 / 10 / 2025, page 43 / 87 A 35 / 45 torque converter is connected to the motor and directly to the electric motor. A torque is applied by the motor to the torque converter to generate a modified torque. The method also includes applying the modified torque to the electric motor via the torque converter. The method also includes rotating a rotor of the electric motor using the modified torque. The method also includes rotating a drive shaft connected to the rotor using the rotor. The method also includes rotating a transmission of the transport truck using the drive shaft. The method also includes rotating a differential of the transport truck using the transmission. The method also includes propelling the wheels of the transport truck using the differential.

[00123] The method described above can be varied. For example, the method above may also include receiving a command to brake the transport truck. In the extended example, the method may also include giving a command to the torque converter to apply a negative torque to the electric motor to cause the rotor to rotate in the opposite direction. Thus, energy is generated when the rotor rotates in the opposite direction. In the extended example, the method may also include routing the energy to an inverter connected to the electric motor. In the extended example, the method may also include routing the energy from the inverter to a battery connected to the inverter.

[00124] In another variation of the method in FIG. 10, the transport truck may include an inverter connected to the electric motor. In this case, an extended method also includes receiving a command to shift the transmission. The extended method also includes removing, by the inverter, the torque from the electric motor while the transmission shifts. The removal may involve the inverter giving a command for the electric motor to unlock at least one of the torque converter, the drive shaft, and the transmission.

[00125] Other variations are possible. Thus, the examples above Petition 870250089877, dated 02 / 10 / 2025, page 44 / 87 36 / 45 does not necessarily limit other modalities.

[00126] FIG. 11 shows a flowchart of a method for adapting a haul truck, according to one or more embodiments. The method of FIG. 11 can be performed to adapt an existing combustion engine haul truck to a hybrid haul truck, such as the haul truck examples shown in FIGS. 2 to 9. Once adapted, the hybrid haul truck can be operated according to the method of FIG. 10. The method of FIG. 11 can be characterized as a method of adapting a haul truck including a chassis, an engine connected to the chassis, a torque converter connected to the engine, a drive shaft directly connected to the torque converter, a transmission directly connected to the drive shaft, a differential connected to the transmission and wheels connected to the differential.

[00127] Step 1100 involves decoupling the torque converter drive shaft. Decoupling the torque converter drive shaft can be done by pulling, cutting, or otherwise disengaging the torque converter drive shaft.

[00128] Step 1102 involves removing a length of the drive shaft to form a shortened drive shaft. The length of the drive shaft can be removed by cutting through the drive shaft at a predetermined position along the length of the drive shaft.

[00129] Step 1104 involves connecting an electric motor directly to the torque converter or directly to the transmission. The motor can be connected to the torque converter or transmission by means of mounting brackets, such as mounting bracket 704 shown in FIG. 7 and FIG. 8. The bolts can extend through the mounting brackets and into the torque converter or transmission. Petition 870250089877, dated 02 / 10 / 2025, page 45 / 87 37 / 45 Note that the bolts may be long enough, or corresponding mounting plates may be attached to the torque converter or transmission, so that a gap may exist between the electric motor and the torque converter or transmission. The existence of a gap between the electric motor and the torque converter or transmission does not negate the fact that the electric motor is directly connected to the torque converter or transmission, because the bolts connecting the components are in touch with respect to the electric motor and the torque converter or transmission.

[00130] In one embodiment, the electric motor can be directly connected to the engine, in a manner similar to that described above in relation to the torque converter or transmission. Thus, step 1104 also contemplates the possibility of the electric motor being directly connected to the engine.

[00131] Step 1106 involves connecting the shortened drive shaft to the electric motor so that the torque converter is reconnected to the transmission via the electric motor and the shortened drive shaft. Thus, the drive shaft may still be present, extending from one end of the electric motor. The other end of the electric motor is connected to the torque converter (or motor) or to the transmission.

[00132] The method in FIG. 11 can be further varied. For example, the method may also include installing an inverter module connected to the chassis and the electric motor. In this case, the method may also include connecting a battery to the inverter. Other variations are possible, such as changing the chassis to accommodate the electric motor. Thus, the example in FIG. 11 is not necessarily limited to the examples given above.

[00133] The method in FIG. 11, together with the components described in relation to FIG. 1 through FIG. 9, can be used to adapt Petition 870250089877, dated 02 / 10 / 2025, page 46 / 87 38 / 45 tar existing haul trucks from various other equipment manufacturers and size classes. Thus, one or more modalities can reduce costs by retrofitting mechanical haul trucks while reducing overall emissions. The design of one or more modalities can be used, for example, to retrofit Caterpillar (CAT) 793 and CAT 777 haul trucks.

[00134] A specific example of adapting transport trucks, consistent with the method in FIG. 11, is now provided. The specific example provided below does not limit other modalities or methods of adapting combustion engine transport trucks into hybrid transport trucks.

[00135] A mine operator operates a fleet of fifty CATERPILLAR® CAT 793® haul trucks. The mine has a 30% greenhouse gas reduction initiative by 2030. CATERPILLAR® does not offer emission reduction systems for this current generation diesel haul truck. The current solution would be to scrap the fifty CAT 793® haul trucks and purchase fifty new diesel-electric haul trucks that offer an emission reduction system. The CAT 793® uses a 2,500 horsepower (HP) diesel engine that can create 6,700 foot-pounds (ft-pounds) of torque.

[00136] The available space for an electric assist motor is 20 inches long. The mine profile requires at least 225kW of electric assist motor to meet the 30% emissions reduction target. Available motors from other suppliers that fit the desired space are not rated to handle the 6700 ft-lbs of torque from the motor plus the torque of the electric motor. Available drives from other suppliers in this class are not suitable for the power level of the haul truck, do not include a system controller, and require modifications. Petition 870250089877, dated 02 / 10 / 2025, page 47 / 87 39 / 45 positions to operate safely in the available space. Supporting items, such as a thermal management system, are not included.

[00137] In contrast, the engine of the mechanical haul truck hybrid system in FIG. 7 and FIG. 8 is designed with high-strength alloys to handle the engine torque plus the electric motor torque with adequate engineering tolerance margin. The electric motor is mechanically designed to fit directly into the available space, with only minor structural changes to the haul truck. The drive system is developed in conjunction with the electric motor to provide the power levels used during intensive use. The algorithms and hardware used to control the motor fit correctly into the floor of the haul truck for quick access and contain supporting thermal management. The algorithms and hardware also include system controller functionality that determines how and when to energize the electric motor to achieve reduced emissions and fuel consumption while maximizing battery life.

[00138] Thus, the mine operator can adapt its existing fleet with the hybrid mechanical haul truck system and continue to utilize the investment made in purchasing the fleet. The resulting hybrid haul truck system also helps the mine operator achieve emissions reduction targets, where the only other alternative might be to scrap the fleet and purchase new haul trucks at a substantially higher cost.

[00139] Although the various steps in the flowcharts of FIG. 10 and FIG. 11 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. Petition 870250089877, dated 02 / 10 / 2025, page 48 / 87 40 / 45

[00140] One or more modalities described in this document have several benefits. For example, many haul trucks utilize autonomous driving systems. These systems can use a series of sensors and predefined routes to operate the haul trucks without drivers. Any changes in the way the haul truck operates may imply changes to the autonomous driving system. However, one or more modalities allow the haul truck to continue operating as before, but with a hybrid system. In other words, one or more modalities allow the hybrid system to be retroactively added to the haul truck without requiring any operational modifications to the haul truck. Consequently, the autonomous drive system can continue to function normally, as before the adaptation, without the need for any testing or recertification.

[00141] One or more forms are not similar to conventional hybrid motor vehicles. For example, the electric motor in one or more forms may have at least five times the power of an automotive system, operating at a lower RPM, leading to different electric motor designs and requirements than those described above. Furthermore, haul truck transmissions and torque converters are different from passenger vehicle transmissions and are much more expensive. Most automotive hybrid systems are integrated into the transmission, whereas when retrofitting a haul truck, the transmission is kept separate from the hybrid systems (e.g., the electric motor). Adding a hybrid system to an existing haul truck without a replacement transmission or torque converter, as described above, is a cost-effective way to retrofit a combustion engine haul truck to become a hybrid haul truck.

[00142] Another distinguishing fact that differentiates transport trucks Petition 870250089877, dated 02 / 10 / 2025, page 49 / 87 41 / 45 The advantage of hybridization compared to hybrid systems for automobiles is that, in a transport truck, as the transmission changes gear, the torque converter is unlocked to decouple the motor from the transmission. Unlocking the torque converter to decouple the motor from the transmission reduces wear on the transmission clutches. Due to the positioning of the electric motor, one or more modes (via the power controller 228 in FIG. 2) can detect the unlocking of the torque converter and immediately remove torque from the drive shaft during movement. This procedure does not occur with automotive hybrid systems that are integrated into the transmission.

[00143] In another adaptation procedure for a hybrid truck transport system, the diesel engine drive shaft can be removed and a high power density electric motor can be coupled to the engine's torque converter output. The electric motor is described above and is considered a high power density electric motor due to the number of poles present in the electric motor, as described above. The high power density electric motor acts as an extension of the drive shaft and thus handles the sum of the torque produced by the electric motor and the torque produced by the engine. Consequently, a strong electric motor shaft is provided that uses high-strength alloys (e.g., 4340 steel, as described above) that are not found in other electric motors that fit the available space.

[00144] The electrical design of the electric motor, in one or more forms, may be unique to fit the allocated space and operate with the high-strength shaft. A shorter drive shaft (compared to the original transport truck) may be placed on the opposite side of the electric motor that couples the electric motor to the transmission.

[00145] A battery and a specialized drive system Petition 870250089877, dated 02 / 10 / 2025, page 50 / 87 42 / 45 can be fitted to the transport truck to power and control the electric motor. The drive system can be designed to interface with the battery, the system controller, and to control the speed and torque of the electric motor. The drive system can operate in the harsh, high-vibration, and extreme temperatures of a transport truck, providing maximum reliability and ease of service. The drive system can thus include the components used to provide a complete, quick-working solution for adapting transport trucks to hybrid technology.

[00146] A unique liquid cooling thermal management system and pump can be included in the drive to maintain the power electronics, battery, and optionally the motor within a desired operating temperature range, allowing the system to be sealed from external elements. A system controller is included to control the flow of power between the battery, motor, electric motor, and drive system.

[00147] 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 first predetermined range of angles for one embodiment, but they may also be approximately congruent if the values ​​of the two angles are within a second predetermined range of angles for another embodiment. The average person skilled in the art is able to assess what is an acceptable engineering tolerance for a specific product and is therefore able to determine the appropriate tolerance. Petition 870250089877, dated 02 / 10 / 2025, page 51 / 87 43 / 45 peace of mind to assess how to determine the variance of the measurement contemplated by the term about.

[00148] 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.

[00149] 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 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.

[00150] The figures show diagrams of modalities that are Petition 870250089877, dated 02 / 10 / 2025, page 52 / 87 44 / 45 according to the disclosure. The embodiments of 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 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.

[00151] 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.

[00152] 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 of the items with any number of each item, unless expressly indicated otherwise.

[00153] In the description above, several specific details are established in order to provide a more complete understanding of one or more modalities. However, it will be evident to those versed in the technique that one or more modalities can be practiced without these specific details. In other cases, well-defined characteristics Petition 870250089877, dated 02 / 10 / 2025, page 53 / 87 45 / 45 known embodiments have not been described in detail to avoid unnecessarily complicating the description. Furthermore, other embodiments not explicitly described above may be conceived that do not depart from the scope of one or more embodiments as disclosed in this document. Consequently, the scope of one or more embodiments shall be limited only by the appended claims.

Claims

1. A vehicle characterized in that it comprises: a chassis; a motor connected to the chassis; a torque converter directly connected to the motor; an electric motor having a first side and a second side directly connected to the torque converter, opposite the motor, wherein: the electric motor further comprises a rotor having an annular shaft cavity, the electric motor further comprises a first diameter equal to or smaller than a second diameter of the torque converter, and the electric motor is connected to the torque converter through the annular shaft cavity; a drive shaft directly connected to the electric motor, opposite the torque converter, wherein the drive shaft is operationally disposed in the annular shaft cavity; a transmission connected to the drive shaft; a differential connected to the transmission; and a plurality of wheels connected to the differential.

2. Vehicle according to claim 1, characterized in that: the electric motor further comprises a stator structure arranged around the circumference of the electric motor, the electric motor comprises a first side facing away from the torque converter and a second side facing towards the torque converter, the electric motor comprises a mounting bracket directly fixed to the stator structure near the second side of the electric motor, and Petition 870250089877, dated 10 / 02 / 2025, page 55 / 87 2 / 8 the electric motor is connected to the torque converter via the mounting bracket.

3. Vehicle according to claim 1, characterized in that: the electric motor comprises a first side facing away from the torque converter and a second side facing the torque converter; the electric motor further comprises a seal connected to the first side of the electric motor, and the seal at least partially prevents external access to the plurality of bearings connected to the rotor inside the electric motor.

4. Vehicle according to claim 1, characterized in that the electric motor further comprises a stator structure arranged around a circumference of the electric motor, wherein the electric motor comprises a first side facing away from the torque converter and a second side facing towards the torque converter, wherein a space is defined between the electric motor and the torque converter, and wherein the vehicle further comprises: a fluid transmission line connected to the stator structure near the second side of the electric motor, wherein the fluid transmission line is located at least partially within the space; a fluid source connected to the fluid transition line and storing a fluid; and a cooling system arranged within the stator structure and arranged to distribute the fluid through the cooling system.

5. Vehicle, according to claim 1, characterized in that it further comprises: Petition 870250089877, dated 02 / 10 / 2025, page 56 / 87 3 / 8 an inverter connected to the electric motor; and a battery connected to the inverter.

6. Vehicle according to claim 1, characterized in that the vehicle comprises a transport truck.

7. Vehicle according to claim 6, characterized in that the chassis comprises: a pair of longitudinal structural members disposed between a front of the transport truck and a rear of the transport truck; a central structural crossmember disposed between the pair of longitudinal structural members; and wherein the electric motor is entirely disposed ahead of the central structural crossmember, relative to the front of the transport truck, and under the central structural crossmember, relative to a direction of gravity.

8. Vehicle according to claim 1, characterized in that it further comprises: a power controller connected to the electric motor, the power controller configured to control the power coming from or consumed by the electric motor.

9. Vehicle according to claim 8, characterized in that the power controller further comprises: a plurality of inverter modules connected to each other and configured to control a power level output by the electric motor.

10. Vehicle, according to claim 1, characterized in that it further comprises: a cabin connected to the chassis; and a user interface disposed within the cabin, wherein: Petition 870250089877, dated 02 / 10 / 2025, page 57 / 87 4 / 8 the user interface is configured to allow monitoring and configuration of the electric motor or an inverter connected to the electric motor, and the user interface is configured to control a power output from the inverter to the electric motor.

11. Vehicle according to claim 1, characterized in that it further comprises: a platform connected to the chassis; a power cabinet connected to the platform; and an electronic drive and liquid cooling system disposed within a first section of the power cabinet, wherein the liquid cooling system is further connected to the electric motor.

12. Vehicle according to claim 11, characterized in that it further comprises: a plurality of inverter modules connected to each other within a second section of the power cabinet, wherein the plurality of inverter modules is configured to control a power level output by the electric motor.

13. Vehicle according to claim 12, characterized in that it further comprises: a system controller and a wiring module within a third section of the power cabinet; a maintenance interface connected to the system controller and the wiring module; and an access door connected to the system controller and the wiring module and configured to grant access within the system controller and the wiring module.

14. Vehicle, according to claim 13, characterized in that the second section is adjacent to the first section and Petition 870250089877, dated 10 / 02 / 2025, page 58 / 87 5 / 8 in which the third section is adjacent to the second section.

15. A vehicle characterized in that it comprises: a chassis; a motor connected to the chassis; a torque converter directly connected to the motor; a drive shaft directly connected to the torque converter; an electric motor connected to the drive shaft, opposite the torque converter, wherein: the electric motor further includes a rotor having an annular shaft cavity; the electric motor further includes a first diameter equal to or smaller than a second diameter of the torque converter; the electric motor is connected to the drive shaft through the annular shaft cavity; and a transmission connected to the electric motor; a differential connected to the transmission; and a plurality of wheels connected to the differential.

16. Vehicle according to claim 15, characterized in that the vehicle comprises a transport truck.

17. Vehicle according to claim 16, characterized in that the chassis comprises: a pair of longitudinal structural members disposed between a front of the transport truck and a rear of the transport truck; a central structural crossmember disposed between the pair of longitudinal structural members; and wherein the electric motor is entirely disposed behind the central structural crossmember, in relation to the rear of the transport truck and under the central structural crossmember, in relation to a gravity direction.

18. A method for adapting a transport truck, characterized in that it comprises a chassis, an engine connected to the chassis, a torque converter connected to the engine, a drive shaft directly connected to the torque converter, a transmission directly connected to the drive shaft, a differential connected to the transmission, and a plurality of wheels connected to the differential, the method comprising: decoupling the drive shaft from the torque converter; removing a length of the drive shaft to form a shortened drive shaft; connecting an electric motor directly to the torque converter or directly to the transmission; and connecting the shortened drive shaft to the electric motor so that the torque converter is reconnected to the transmission via the electric motor and the shortened drive shaft.

19. Method according to claim 18, characterized in that it further comprises: installing an inverter module connected to the chassis and the electric motor; and connecting a battery to an inverter.

20. Method according to claim 18, characterized in that it further comprises: installing a power cabinet disposed within a truck cab; installing an electronic drive and liquid cooling system disposed within a first section of the power cabinet, wherein the liquid cooling system is further connected to the electric motor; installing a plurality of inverter modules connected to each other within a second section of the power cabinet, wherein the plurality of inverter modules is configured to control a power level output by the electric motor.Install a system controller and wiring module within a third section of the power cabinet; install a maintenance interface connected to the system controller and wiring module; and install an access door connected to the system controller and wiring module and configured to grant access within the system controller and wiring module.

21. A method of operating a transport truck, characterized in that it comprises an engine, the method comprising: energizing a drive system and the engine of the transport truck; modifying, by means of a torque converter connected to the engine and directly connected to the electric motor, a torque applied by an engine to the torque converter to generate a modified torque; applying, by means of the torque converter, the modified torque to the electric motor; rotating, by the modified torque, a rotor of the electric motor; rotating, with the rotor, a drive shaft connected to the rotor; rotating, with the drive shaft, a transmission of the transport truck; rotating, with the transmission, a differential of the transport truck; and propelling, with the differential, a plurality of wheels of the transport truck.

22. The method, according to claim 21, is characterized by the fact that it further comprises: receiving a command to brake the transport truck; giving a command to the torque converter to apply a negative torque to the electric motor to cause the rotor to rotate in the opposite direction, wherein energy is generated when the rotor rotates in the opposite direction; routing the energy to an inverter connected to the electric motor; and routing the energy from the inverter to a battery connected to the inverter.

23. A method according to claim 22, characterized in that the transport truck further comprises an inverter connected to the electric motor and in which the method further comprises: receiving a command to shift the transmission; and removing, by the inverter, the torque from the electric motor while the transmission shifts, wherein the removal comprises the inverter giving a command for the electric motor to unlock at least one of the torque converter, the drive shaft and the transmission.

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