Payload carrier

Abstract

A payload carrier (10) includes a support subassembly (20) and an integrated tray device (12). The support subassembly (20) is secured to, extends from, and / or is suspended from the integrated tray device (12). The integrated tray device (12) forms part of the structural chassis of the payload carrier (10) and thus is designed to support the payload carrier (10) and to increase the flexural rigidity, torsional rigidity and impact strength of the payload carrier (10). Generally, an integrated tray device (12) includes a tray (14) and a support structure (18).

Description

Technical Field

[0001] The present invention relates to the field of hauling, carrying, conveying and / or transporting payloads. The invention extends to various forms of payloads. In one embodiment, the invention extends to the field of raw material handling, and in particular to vehicles used in the process of hauling, carrying, conveying and / or transporting such raw materials. In other examples, the payload can be cargo, people or livestock, etc. Generally, the present invention relates to relatively lightweight structures for vehicles used to haul, carry, convey and / or transport payloads, but the invention is not particularly limited to use with vehicles, and other forms of container or carrier structures are also provided. The invention also extends to methods of designing such low weight structures. Background Art

[0002] Growing concern about energy efficiency and the environmental impact of the hauling, carrying, conveying, and / or transportation industries is driving demand for more efficient energy consumption in vehicles. To this end, attention is shifting toward smaller, more efficient vehicles (in this case, smaller vehicles facilitate the implementation of more energy-efficient technologies, greater autonomy, and, in some cases, renewable energy sources). Furthermore, there is a focus on improving the energy efficiency of surrounding systems and processes, leading to an overall focus on energy expenditure and efficiency. For example, vehicles powered by renewable energy sources such as electricity or hydrogen may offer a means of utilizing "clean" energy for hauling, carrying, conveying, and / or transportation. However, the range of these vehicles is largely dependent on the vehicle's weight.

[0003] One aspect that significantly contributes to the weight of conventional hauling, carrying, conveying and / or transporting vehicles is the weight associated with structural components such as the chassis, undercarriage, suspension system, etc. Typically, these components have a considerable weight necessary to withstand the typical loads, shocks, vibrations, fatigue, etc., that are encountered due to the magnitude of the loads carried by the vehicle and the environment in which the vehicle operates.

[0004] In many cases, passenger vehicles utilize a so-called monocoque construction, integrating the structural components of the vehicle into the body or shell. Due to the relatively small size of the loads carried by these types of vehicles, this is possible and results in significant weight savings. However, to date, the use of monocoque construction has been limited. For example, higher performance passenger vehicles (such as sports cars, SUVs, pickup trucks, etc.) that are associated with higher stresses and loads still typically use ladder frames or non-load-bearing body structures to adequately handle the loads associated with vehicle use. The use of monocoque construction in large hauling, carrying, conveying and / or transport vehicles remains to be explored. To date, there has been a lack of implementation of alternative low-weight construction methods for structural components of hauling, carrying, conveying and / or transport equipment.

[0005] Reducing the gross vehicle weight is believed to have a profound impact on the overall energy consumption associated with hauling, carrying, conveying, and / or transporting a payload. This includes reducing the vehicle's empty weight relative to its payload. Using this lower weight is believed to be associated with increased productivity, operational flexibility, and overall efficiency.

[0006] Likewise, it is believed that reducing the overall weight of structural components may make them more suitable for use with alternative, environmentally efficient and / or renewable energy sources.

[0007] It is therefore an object of the present invention to provide a payload carrier which will at least partially address the above-mentioned disadvantages or facilitate the above-mentioned potential improvements.

[0008] It is another object of the present invention to provide a payload carrier that will be a useful alternative to existing payload carriers. Summary of the Invention

[0009] According to a first aspect of the present invention, there is provided a payload carrier comprising:

[0010] support subassembly; and

[0011] Integrated tray unit,

[0012] Wherein the support subassembly is secured to and / or extends from the integrated tray arrangement, and wherein the integrated tray arrangement forms part of a structural chassis of the payload carrier.

[0013] An integrated pallet device may include a pallet and a support structure. The pallet may operatively interact with the support structure to facilitate load transfer between the support structure and the pallet. The support structure may be positioned toward the outside of the pallet. The support structure may be made of a polymer composite or a metal (e.g., steel, stainless steel, or aluminum). The support structure may be designed and / or formed based on an analysis-driven design approach.

[0014] The support structure can take the form of an exoskeleton forming a bracket within which the tray is housed, or the bracket can be integrally formed with the tray. The support structure can include at least a first circumferentially extending member. The circumferential member can be positioned circumferentially around the open top portion of the tray. The support structure can also include longitudinal ribs that extend at least partially under the tray and support the tray from below. In some examples, the support structure can include at least two central longitudinal ribs and two outer longitudinal ribs. The longitudinal ribs can extend between opposing portions of the circumferentially extending member, and in some cases, the longitudinal ribs can be fixed to or integrally formed with the circumferentially extending member.

[0015] The periphery of the open top of the pallet may be reinforced by a rim arrangement comprising a single rim portion or a plurality of interlocking rim portions.

[0016] In some examples, the support structure may include a plurality of cross-extending members and interconnecting members.

[0017] The support structure may further comprise a first sub-frame and a second sub-frame extending in a forward and rearward direction relative to the pallet, respectively. The support structure may further comprise a shear plate extending forward and a shear plate extending rearward. The shear plate may extend in a plane parallel to a surface on which the payload carrier is operably supported. The shear plate may be substantially trapezoidal when viewed from the top. The thickness of the shear plate may be in the range of 2 mm to 6 mm, preferably about 4 mm. The shear plate may be made of metal or a composite material. The shear plate may be secured directly or indirectly to the pallet.

[0018] The payload carrier may include at least a first external anchoring device extending beyond the outer surface of the pallet. The external anchoring device may include an outer plate and a back plate. A portion of the external anchoring device may extend at least partially through the pallet and between the outer plate and the back plate to sandwich the pallet between the outer plate and the back plate. The outer plate and / or the back plate may be bonded to the pallet. The external anchoring device may be made of a metal such as steel or stainless steel. The external anchoring device may be fixed relative to the support structure.

[0019] The support subassembly may include a drivetrain or chassis subassembly including a set of wheels or a set of tracks. The payload carrier may be configured as a hauling vehicle. At least some of the wheels or tracks may be driven.

[0020] The tray may have a shape that is U-shaped or substantially hemispherical in cross-section. The tray may define a trough portion and a sidewall portion. The wall thickness of the trough portion may exceed the wall thickness of the sidewall portion, thereby increasing the bending stiffness, torsional stiffness, and impact strength of the trough portion. The wall thickness of the sidewall portion may range from 4 mm to 12 mm, preferably approximately 8 mm. The wall thickness of the trough portion may range from 8 mm to 20 mm, preferably approximately 12 mm.

[0021] The pallet may be made of: a metal, such as steel, stainless steel and aluminium; a composite material; or a layered material comprising at least one metal layer and one composite layer.

[0022] The pallet may comprise a plurality of pallet layers, at least one of which may be made of a composite material.The pallet may be designed and / or formed according to an analysis-driven design method.

[0023] In one example, the payload carrier has a pallet layer including:

[0024] Main pallet layer; and

[0025] A liner layer is received on the main tray layer.

[0026] The main pallet layer can include a steel layer or a polymer layer. The lining layer can include a single-piece molded layer; ii) a layer sprayed onto the main pallet layer; iii) a layer cast onto the main pallet layer; or iv) a layer composed of adjacent bolted segments. The lining layer can include a steel layer or a polymer layer. The polymer layer can include a fiber-reinforced polymer layer, wherein the fibers of the fiber-reinforced polymer layer include glass fibers, carbon fibers, or natural fibers.

[0027] The operative bottom portion of the main pallet layer may comprise a locally thickened wall portion.The impact plate may optionally be sandwiched between the liner layer and the operative bottom portion of the pallet layer.

[0028] The outer surface of the pallet may be lined with a separate protective shield made of metal (such as steel, stainless steel or aluminum) or a composite material.

[0029] The integrated pallet device may have an open top configured to receive a payload therethrough. Typically, the payload is in the form of raw material.

[0030] The integrated tray device may include measurement sensors for measuring stress, strain, acceleration, temperature or vibration. The measurement sensors may include strain gauges, accelerometers or thermocouples.

[0031] The integrated tray device may have a roof portion and a closable opening configured as a door.

[0032] According to a second aspect of the present invention, there is provided a heavy vehicle comprising a frame made of a composite material and shaped and designed based on an analysis-oriented design method.

[0033] Furthermore, according to the second aspect of the present invention, the frame may be made of a polymer material in the form of a fiber-reinforced polymer material, wherein the fibers include glass fibers, carbon fibers, or natural fibers.

[0034] The frame may comprise an integrally formed lattice structure.The frame may be formed by or with the aid of a moulding process.

[0035] The frame may comprise a hollow frame member formed from a foam insert provided in a mould used in the moulding process.

[0036] The frame may include one or more measurement sensors to measure stress, strain, acceleration, temperature and / or vibration applied to or experienced by the frame. The measurement sensors may include strain gauges, accelerometers and / or thermocouples. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] The present invention will now be described in more detail, by way of example only, with reference to the accompanying drawings, in which:

[0038] Figure 1 shows a front perspective view of a payload carrier according to a first non-limiting example embodiment of the present invention;

[0039] Figure 2 Shows the formation Figure 1 A perspective view of an integrated pallet assembly as a portion of a payload carrier, wherein a pallet within the integrated pallet assembly is partially broken away;

[0040] Figure 3 Shown with Figure 1 A detailed perspective view of a pallet-related fixture of an integrated pallet assembly of a payload carrier;

[0041] Figure 4 Shown Figure 3 The back plate of the fixing device is located toward Figure 1 the inside of the pallet of the payload carrier;

[0042] Figure 5 Shown Figure 1 a perspective view of an alternative embodiment of an integrated pallet arrangement for a payload carrier, wherein the pallet is again partially cut away to reveal its interior layers and includes detailed views of some partially cutaway parts;

[0043] Figure 6 Shows the formation Figure 1 a perspective view of yet another alternative embodiment of an integrated pallet assembly of a portion of a payload carrier, wherein the integrated pallet assembly has been partially broken away;

[0044] Figure 7 Shown with Figure 6 Detailed views of fixtures associated with example embodiments of integrated tray devices;

[0045] Figure 8 shows a simplified front perspective view of a payload carrier according to a second non-limiting example embodiment of the present invention, the payload carrier being shown in an unloaded or empty state;

[0046] Figure 9 Shown Figure 8 A simplified front perspective view of a payload carrier after loading with raw materials;

[0047] Figure 10 shows a front perspective view of a payload carrier according to a second non-limiting example embodiment of the present invention, the payload carrier being shown in use while carrying a payload in the form of raw material, such as mined ore;

[0048] Figure 11 Shown Figure 10a perspective view of a payload carrier with its side doors in an open configuration to allow for operable unloading of the payload;

[0049] Figure 12 Shown Figure 10 A side view of a payload carrier;

[0050] Figure 13 Shown Figure 10 A front view of the payload carrier;

[0051] Figure 14 Shows the formation Figure 10 a top perspective view of an integrated tray assembly of a portion of a payload carrier;

[0052] Figure 15 Shown Figure 14 A bottom perspective view of the integrated tray assembly;

[0053] Figure 16 Shown Figure 14 A top view of the integrated tray assembly; and

[0054] Figure 17 Shown Figure 14 a bottom perspective view of an integrated tray assembly and support subassembly including a suspension subassembly forming part of a drive train for a payload carrier;

[0055] Figure 18 shows a schematic top perspective view of a heavy vehicle according to the invention; and

[0056] Figure 19 Shown Figure 18 Bottom perspective view of a heavy vehicle. DETAILED DESCRIPTION

[0057] Before explaining any embodiments of the present invention in detail, it should be understood that the application of the present invention is not limited to the construction details and component arrangements set forth in the following description or shown in the following figures. The present invention is capable of other embodiments and can be practiced or implemented in various ways. In addition, it should be understood that the phrases and terms used herein are for descriptive purposes only and should not be considered as limiting. As used herein, "include," "comprise," or "have" and their variations are meant to include the items listed below and their equivalents, as well as additional items. Unless otherwise specified or limited, the terms "mount," "connect," "engage," and their variations are used broadly to include direct and indirect mounting, connection, support, and coupling, and are therefore intended to include direct connections between two components without any intervening components, as well as indirect connections between components with one or more other components interposed therebetween. In addition, "connect" and "engage" are not limited to physical or mechanical connections or couplings. In addition, words such as "lower," "upper," "upward," "downward," and "downward" indicate directions in the accompanying drawings to which reference is made. Terms include the words specifically mentioned above, their derivatives, and words or similar meanings. It should be noted that as used in this specification and the appended claims, the singular forms "a," "an," and "the," as well as any use of any word in the singular, include plural referents unless expressly and unequivocally limited to one referent. As used herein, the term "include" and its grammatical variations are intended to be non-limiting, such that the recitation of items in a list does not exclude other like items that can be substituted or added to the listed items.

[0058] Referring to the accompanying drawings, wherein like numerals denote like features, a payload carrier (or simply "carrier") according to the present invention is generally designated by reference numeral 10, while a first non-limiting example of the carrier is designated in the drawings by reference numeral 10.1, and a second non-limiting example of the carrier is designated in the drawings by reference numeral 10.2. It should be understood that, unless otherwise indicated, features described with respect to one non-limiting example are compatible and interchangeable with respect to another non-limiting example.

[0059] Payload carrier 10 may take a variety of forms and is not limited to the examples shown in the figures or discussed herein.

[0060] Generally speaking, the carrier 10 includes a support subassembly 20 and an integrated tray assembly 12. The support subassembly 20 is secured to, and / or extends from, or is suspended from the integrated tray assembly 12. Furthermore, the integrated tray assembly 12 forms part of or represents the structural chassis of the carrier 10. In some cases, the integrated tray assembly 12 includes a tray 14 and a support structure 18.

[0061] The tray 14 defines a volume 16 which, in use, receives a payload 19 (e.g. Figure 10). A support structure 18 is located or formed toward the outside of the tray 14. The support structure 18 can take a variety of forms, some of which are described below. In some cases, the support structure 18 can be omitted, and the structural integrity of the integrated tray assembly 12 can be provided by the specific configuration of the tray 14, as described below.

[0062] Because the tray 14 forms part of the integrated tray assembly 12, the tray 14 is configured to provide structural integrity, rigidity, and support to the payload carrier 10. For example, the tray 14 is configured to provide torsional and bending stiffness to the integrated tray assembly 12. This is achieved through the design of the tray 14, and more specifically, through the material selection and shape and configuration of the tray 14. This will be discussed more fully below.

[0063] The carrier 10 shown in the figures takes the form of a haul carrier, with a pallet 14 having an open top 26 for receiving a payload 19, typically in the form of raw material such as rock fragments or mined ore.

[0064] In some examples, the tray 14 and support structure 18 are made of metal, such as steel, stainless steel, or aluminum. The use of metal in the manufacture of the tray 14 and support structure 18 is advantageous due to its low cost, ability to withstand penetration, and rigidity. However, in some cases, metal does result in relatively high impact loads being transferred to other parts of the structural chassis.

[0065] In other examples, both the tray 14 and the support structure 18 are made of composite materials. In the manufacture of the tray 14 and the support structure 18, a combination of metal and composite materials is theoretically possible.

[0066] For the present purposes, the term "composite material" will be understood as a material composed of various types of materials, at least some of which are polymeric, non-metallic materials. In some cases, composite materials may include metallic components, inserts, or reinforcements. Commonly, composite materials include glass, carbon, or natural fiber composites, which are advantageous due to their relatively low weight. That said, glass, carbon, or natural fiber composites are generally more brittle than steel.

[0067] In another alternative example, some embodiments of which are discussed more fully below, the pallet 14 is made of a layered or sandwich material. In some cases, some of the layers may include metal layers. This layered material combines the stiffness and energy absorption capabilities of steel with reduced load and impact distribution to the rest of the integrated pallet assembly 12. However, the costs associated with layered materials are higher than the costs of metal or composite materials alone.

[0068] The integrated pallet assembly 12 is designed according to an analysis-driven design or research approach. This approach revolves around configuring the integrated pallet assembly 12, or, where relevant, the pallet 14, based on load paths related to the forces exerted on the carrier 10, and on the results of in-use load cases, impact, wear, and abrasion testing. Furthermore, the components or parts of the integrated pallet assembly 12 are selected with these two aspects in mind. For example, in this example, one of the load cases used for design involves loads related to the forces exerted on the pallet 14 by the payload, which are related to the payload's physical weight. Another load case involves point loads transmitted to the pallet 14 by rock fragments, wear caused by displacement of the payload relative to the pallet 14 during loading or use, and cyclic strain and vibration caused during loading, unloading, and normal operation. Therefore, an analysis-driven design or research approach requires a comprehensive approach when it comes to component sizing and material selection. It examines the different parts of the integrated pallet assembly 12 independently and, based on the aforementioned analysis, dictates specific sizing and material selection to achieve overall or global efficiency from the perspectives of load bearing, fatigue life, and weight. For example, even though certain components of the integrated pallet arrangement 12 may be made from materials with higher wear resistance, these components and materials are still considered from the perspective of load-bearing capacity. Adjacent areas may see lower wear and fatigue and may therefore be manufactured from another material with more favorable weight characteristics, etc. This approach contrasts with conventional design methods, where different load scenarios are considered independently. For example, conventional design methods would traditionally require designing for load-bearing capacity on the one hand and separately consider aspects such as wear and abrasion or impact absorption on the other hand, with auxiliary materials such as linings or auxiliary components such as dampers being provided to address this issue. By looking at these aspects independently, the design obtained using conventional methods may be less efficient, heavier and more expensive.

[0069] The frame may generally take the form of an interconnected or monolithic lattice structure and may be composed of a plurality of components or subassemblies.

[0070] Importantly, the pallet 14 and support structure 18 interact to transfer loads therebetween, such that both contribute to the structural integrity of the integrated pallet assembly 12. In some cases, portions of the support structure 18 may be secured to the pallet 14, such as by welding or gluing. In other examples, the pallet and support structure may be integrally formed.

[0071] exist Figure 1 and Figure 2In the example shown, support structure 18 is formed as an exoskeleton and is manufactured separately from pallet 14. Here, support structure 18 forms a bracket within which pallet 14 is received and supported. Thus, pallet 14 can be placed on top of support structure 18. Even though manufactured separately, support structure 18 and pallet 14 can be connected together by gluing, using mechanical fasteners, or the like.

[0072] exist Figure 6 and Figure 7 In the example shown, the support structure 18 is integrally formed with the pallet 14 and therefore extends from an outer surface 36 of the pallet 14. In this example, the frame is made of the same material as the outer pallet layer 24 (and in particular a composite polymer material).

[0073] The support structure 18 includes a first circumferentially extending member, a collar member, or a top frame 44 that extends around the pallet near or at the edge 40 and provides circumferential and surrounding support for the pallet 14. The circumferentially extending member 44 comprises a structure having a closed shape to which the upper portion of the pallet 14 can be secured. The circumferentially extending member 44 provides torsional rigidity to the integrated pallet assembly 12 while strengthening and protecting the edges of the pallet 14, particularly during loading.

[0074] The circumferentially extending member 44 is typically made from a single beam member or a plurality of interconnected beam members, and is typically made from a material similar to that of the tray 14 .

[0075] In some cases, such as Figure 1 、 Figure 2 、 Figure 6 and Figure 7 As shown, the support structure 18 also includes a plurality of other laterally extending members 46 and interconnecting members 48 .

[0076] The support structure 18 also includes a plurality of longitudinal ribs, generally designated by the reference numeral 74. These ribs extend beneath the tray 14 and support the tray 14 from below. The longitudinal ribs 74 primarily counteract bending stresses encountered by the tray 14, but also increase the torsional stiffness of the integrated tray assembly 12.

[0077] Specific reference Figures 10 to 17 , the carrier 10.2 typically includes two central longitudinal ribs (indicated by reference numeral 74.1) and two outer longitudinal ribs (indicated by reference numeral 74.2). The central longitudinal rib 74.1 extends from the top frame 44 and is fixed to the top frame 44, or is formed integrally with the top frame 44. In some cases, the outer longitudinal ribs 74.2 also extend from the top frame 44 and are fixed to the top frame 44, or are formed integrally with the top frame 44. However, in some examples (not shown), the outer longitudinal ribs 74.2 extend only around the slot portion of the tray 14 (described below).

[0078] Also specific reference Figures 10 to 17 The support structure 18 further includes a front shear panel 76.1 and a rear shear panel 76.2. The shear panels 76 extend in the forward and rearward directions of the carrier 10.2, respectively, and extend substantially parallel to the surface on which the carrier 10 is operably supported. The inwardly facing edges of the shear panels 76 are secured directly or indirectly to the upper edge of the pallet 14. By being secured relative to the pallet and extending in a plane that is not coincident with the pallet 14, the shear panels add stiffness, rigidity, and structural integrity to the integrated pallet assembly 12. In fact, it has been found that the inclusion of the shear panels can increase the stiffness of the integrated pallet assembly 12 by as much as 29%.

[0079] The shear panels 76 are supported by shear panel support beams 78 .

[0080] The shear plates 76 also perform an auxiliary function by shielding and protecting components of the drivetrain from falling rocks and debris, such as the motor, battery, cooling system, etc. Portions of the shear plates 76 may taper slightly to the sides to prevent rocks and debris from accumulating thereon.

[0081] The thickness of the shear plate 76 is typically about 4 mm.

[0082] The integrated pallet assembly 12 also includes first and second sub-frames 80 that support the drive train, serve as storage compartments for drive train components, and provide further structural rigidity to the integrated pallet assembly 12. The sub-frames 80 may generally comprise box-shaped frames.

[0083] Thus, support structure 18 provides support for various components of carrier 10. For example, suspension subassembly 58 may be mounted to longitudinal ribs 74 and / or subframe 80, while various drivetrain components may be mounted to and supported by shear plate support beams 78 and subframe 80.

[0084] Typically, the cross-section of the tray 14 is substantially U-shaped. As shown, a first non-limiting example includes a tray 14 that is generally hemispherical, concave, or bowl-shaped. This shape provides favorable stress distribution and relatively uniform distribution of clamp stress. A second non-limiting example includes a tray 14 that is substantially U-shaped when viewed from the side.

[0085] Now specific reference Figures 1 to 7 A first non-limiting example of Figure 5 As best shown, the tray 14 is made of a composite material, has a composite structure, and includes multiple layers of material. Figure 5 The structure is sectioned along different lines to selectively show some of the layers.

[0086] The pallet 14 first includes a main or outer pallet layer 24, which is typically made of a polymer material (although in some examples, it is also possible to make the main or outer pallet layer from a metal such as steel). Towards a bottom portion 28 of the pallet 14, the main pallet layer 24 has a locally thickened wall portion 30, which helps and facilitates withstanding the impact caused when the payload is received (or more precisely, dumped) into the volume 16 through the open top 26.

[0087] The pallet 14 also includes a lining layer 32 disposed on the main pallet layer 24 toward the interior of the pallet 14. The lining layer 32 provides further strength and wear resistance to the pallet 14. The lining layer may take one of the following forms (not exhaustive):

[0088] - a single-piece molded layer (usually a polymer material);

[0089] - a layer (usually a polymer material) sprayed onto the master pallet layer;

[0090] - a layer (usually a polymer material) cast onto the main tray layer; or

[0091] - A layer consisting of adjacent bolted segments (usually metal layers, but polymer segments can also be used).

[0092] Using one of the first three iterations of the lining layer 32 is particularly beneficial from a waterproofing perspective and can prevent water, dust, and other foreign matter from entering between the layers of the pallet 14 .

[0093] On the other hand, using the last iteration of the lining layer 32 (ie, the layer consisting of adjacent bolted segments) provides a useful method for replacing a single worn or damaged segment of the lining layer 32.

[0094] Backing layers comprising combinations of two or more of these iterations are possible.

[0095] A metal (steel or stainless steel) strike plate 34 is located toward the bottom portion 28 of the pallet 14 and is sandwiched between the outer pallet layer 24 and the liner layer 32. As such, the strike plate 34 is configured to withstand impacts caused when a payload is received (or more precisely, dumped) into the volume 16 through the open top 26.

[0096] In some cases, the outer surface 36 of the pallet 14 is lined with a protective shield 38, which can also be replaced separately in the event of damage or wear. Typically, the shield is made of steel. The shields 38 are arranged adjacent to each other and are configured to interlock with each other (e.g., by using lap joints or slot connections). The shields 38 can be used to protect the pallet 14 from impact and abrasion, but can also provide structural rigidity and stiffness to the pallet 14. The shield can be secured relative to the pallet 14 by bolts or other suitable fastening mechanisms.

[0097] The edge 40 of the open top 26 is reinforced by a metal rim assembly 42. The rim assembly 42 generally takes the form of a plurality of interlocking metal rim sections that are clamped in place relative to the pallet 14. The rim assembly 42 is provided to protect the pallet 14 from abrasion and impact caused during loading and / or unloading of a payload through the open top 26.

[0098] The carrier includes strategically placed external fixation / connection / anchoring means 50. In some cases, e.g. Figure 7 In the example shown, the fixture 50 is secured directly to or supported by the support structure 18. In this case, the fixture 50 may be bonded to the support structure 18, or may alternatively be secured to the support structure 18 by mechanical fasteners such as bolts and nuts.

[0099] In such Figure 3 and Figure 4 In the other example shown, the fixture 50 includes an outer plate 52, a back plate 54, and a fixing point 56. The outer plate 52, back plate 54, and fixing point 56 are all made of steel or stainless steel. The back plate 54 is positioned toward the interior of the volume, so that the tray 14 is sandwiched and clamped between the outer plate 52 and back plate 54. The fixing point 56 extends beyond the outer surface 36 of the tray 14.

[0100] As previously mentioned, when designing the support structure 18, the load paths are determined taking into account the location of the fixture 50. The fixture 50 is generally provided to secure the support subassembly 20 relative to the pallet 14.

[0101] The incorporation of the fixture 50 provides a beneficial mechanism for distributing the loads associated with the fixture 50 .

[0102] Now specific reference Figures 8 to 17 Here, the pallet 14 includes a side-opening door 82, which facilitates unloading of the payload 19, thereby eliminating the need for alternative on-board unloading hardware (such as tilting equipment, etc.).

[0103] The U-shaped tray 14 is particularly suitable for bearing the stress of the clamp.

[0104] The tray 14 defines a lower portion or trough portion 84 and sidewall portions 86. These different portions experience slightly different load conditions. For example, the trough portion 84 is subject to higher impact, torsional, and bending stresses than the sidewall portions 86. Consequently, the different portions (84, 86) have different wall thicknesses that are selected based on the typical loads that these portions of the tray are subject to and experience (an example of an analysis-driven design approach).

[0105] The trough portion 84 is reinforced to withstand impacts typically encountered during pallet loading (e.g., caused by rocks falling from the loading height into the pallet 14). The trough portion 84 typically has a wall thickness of about 12 mm, although the wall thickness may typically be between about 8 mm and 26 mm.

[0106] Because the sidewall portion 86 tapers, the impact encountered during loading of the raw material is generally lower than that encountered by the trough portion 84. Due to this and the lower bending stress, the wall thickness of the sidewall portion 86 is lower than the wall thickness of the trough portion 84. Typically, the wall thickness of the sidewall portion 86 is approximately two-thirds the wall thickness of the trough portion 84. Thus, the wall thickness of the sidewall portion 86 is typically approximately 8 mm, although the wall thickness is typically between 6 mm and 12 mm.

[0107] In addition to the increased ability to withstand shocks encountered during loading, the increased wall thickness of the trough portion 84 also provides improved bending and torsional stiffness. Furthermore, even with the reduced wall thickness, the side wall portions 86 still contribute to the structural integrity of the pallet 14. However, because the wall portions 86 bear less load, the thinner wall thickness is still sufficient to provide structural integrity while helping to reduce the overall weight of the pallet 14. Thus, the pallet design ensures the ability of the pallet 14 to function as an integral part of the integrated pallet assembly 12.

[0108] The support subassembly 20 generally includes a suspension component 58, drivetrain components (such as a motor, gearbox, fuel system, battery, etc. (not shown)), wheels 60 (which may be replaced by tracks), etc. At least some of the wheels 60 can be driven. Alternatively, the hauling carrier can be a trailer.

[0109] The suspension system 58 may be secured to components of the support structure 18 or, as appropriate, to fixtures 50 that are fixed relative to the pallet 14. Again, it will be appreciated that the integrated pallet assembly 12 plays an integral role in the structural integrity of the carrier 10 and, therefore, the conventional ladder frame assembly typically required to support the vehicle's suspension assembly may be eliminated, at least to a large extent, thereby helping to reduce the vehicle's overall mass.

[0110] The composite structure of the carrier 10 is designed to be protected from damage caused by wear and impact. The lining layer 32 and the outer guard plate 38 are examples of mechanisms for protecting against wear (and to some extent against impact). The thickened portion 30 and the impact plate 34 are examples of mechanisms provided to protect against impact damage. Again, as described above, the specific configuration and use of such protective measures depends on the specific load conditions / scenario, the predetermined impact and load points and the load shape. As described, the specific configuration of such protective measures is designed and specified based on an analytically guided process. However, the provision of such mechanisms and measures enables the use of the carrier and in particular the composite materials used in its construction in heavy applications such as mining and / or material hauling. Therefore, the provision of these mechanisms and measures facilitates the use of composite materials and the realization of the advantages associated therewith.

[0111] It is believed that the use of the pallet 14 as part of the integrated pallet arrangement 12 of the carrier 10 and particularly to help bear the loads and stresses can reduce the overall weight of the vehicle, thereby achieving a reduced vehicle weight to payload ratio. This reduction in vehicle weight is associated with increased efficiency in hauling the vehicle and overall earthmoving operations. It will be appreciated that the use of the pallet 14 as a structural component forming part of the integrated pallet arrangement 12 can reduce the need for a structural frame (e.g., a separate ladder frame, etc.). Additionally, the support structure (forming part of the integrated pallet arrangement 12) can be specifically designed to provide reinforcement in addition to or in addition to the support and structural integrity already provided by the pallet 14. In this way, more efficient use of the support structure can be promoted.

[0112] Additionally, sensors such as strain gauges, accelerometers, and the like can be placed or implanted into structural components. This can provide the ability to monitor data related to the loads experienced by the frame, including shock loads and vibrations, in real time or historically. This data can be used to further optimize structural components using a load path approach, but can also be used to manage preventative maintenance on vehicles. Similarly, the modularity and replaceability of components means that components nearing failure can be easily replaced with new ones.

[0113] The present invention also extends to a heavy vehicle 70 having a frame 72 or other structural component manufactured according to the analytically driven design method detailed above. Figure 18 and Figure 19 The heavy vehicles schematically shown in the figure include dump trucks for hauling raw materials. However, it should be understood that the heavy vehicles 70 can take various forms, such as excavators and other earth-moving machines used in mining and construction, and can also include road vehicles such as trucks, buses, etc. It should be understood that the heavy vehicles do not necessarily need to be associated with the pallet 14, and the load paths used to design the frame according to this method may be related to the forces typically exerted on the frame 72.

[0114] Likewise, the frame 72 is made of a composite material, and the composite material is typically a composite polymer material as discussed above.

[0115] Typically, the frame 72 can be integrally formed and can include a lattice structure. However, in some cases, the frame can include integrally formed modules that can be interconnected to form the frame 72. These modules can be relatively easily replaced when damaged or worn.

[0116] Typically, the frame 72 or modules (as the case may be) can be formed by a molding process. The components of the frame 72 can be hollow. The hollow core of the frame components can be produced by providing a foam insert within the mold during the manufacturing process.

[0117] It is believed that the use of composite materials and interchangeable or modular components in the manufacture of the carrier 10 and heavy vehicle 70 may have various benefits.

[0118] Firstly, the use of composite materials is associated with reduced structural weight, which can therefore play a significant role in reducing the overall energy consumption associated with vehicle use.

[0119] Additionally, these materials can provide greater stiffness and durability, improving the ability to withstand fatigue, shock, and vibration, while worn or damaged parts can be more easily replaced.

[0120] It should be understood that the above description provides only example embodiments of the present invention, and many variations are possible without departing from the spirit and / or scope of the present invention. It can be easily understood from this application that the specific features of the present invention, as generally described and shown in the figures, can be arranged and designed according to various configurations. Thus, providing the description of the present invention and the associated drawings is not intended to limit the scope of the invention, but rather to represent selected embodiments.

[0121] Those skilled in the art will understand that the technical features of a given embodiment can actually be combined with the features of another embodiment, unless otherwise stated or it is obvious that these features are incompatible. In addition, unless otherwise stated, the technical features described in a given embodiment can be isolated from other features of the embodiment.

Claims

1. A payload carrier, comprising: Support subassembly; and Integrated tray unit, Wherein the support subassembly is secured to and / or extends from the integrated tray arrangement, and wherein the integrated tray arrangement forms part of a structural chassis of the payload carrier.

2. The payload carrier of claim 1 , wherein the integrated tray arrangement comprises a tray and a support structure.

3. A payload carrier according to claim 2, wherein the tray operatively interacts with the support structure to facilitate transfer of load between the support structure and the tray.

4. The payload carrier of claim 2 , wherein the support structure is located toward the outside of the pallet; wherein the support structure is made of a polymer composite or a metal, the metal comprising steel, stainless steel, and aluminum; and wherein the support structure is designed and / or formed according to an analysis-driven design approach.

5. The payload carrier of claim 2, wherein the support structure is one of: i) forming an exoskeleton of a cradle within which the pallet is housed; and ii) integrally formed with the pallet.

6. The payload carrier of claim 2, wherein the support structure comprises at least a first circumferentially extending member.

7. A payload carrier according to claim 6, wherein the circumferentially extending members are arranged circumferentially around the open top of the tray.

8. The payload carrier of claim 2, wherein the support structure includes longitudinal ribs extending at least partially beneath the pallet and supporting the pallet from below.

9. The payload carrier of claim 8, wherein the support structure comprises at least two central longitudinal ribs and two outer longitudinal ribs.

10. The payload carrier of claim 2, wherein the longitudinal rib extends between opposing portions of a circumferentially extending member, and wherein the longitudinal rib is secured to or integrally formed with the circumferentially extending member.

11. The payload carrier of claim 2, wherein the edge of the open top of the pallet is reinforced by a rim arrangement comprising a single rim or a plurality of interlocking rim sections.

12. The payload carrier of claim 2, wherein the support structure comprises a plurality of laterally extending members and interconnecting members.

13. The payload carrier of claim 2, wherein the support structure further comprises a first sub-frame and a second sub-frame extending in a forward and rearward direction, respectively, relative to the pallet.

14. The payload carrier of claim 2, wherein the support structure further comprises shear panels extending forwardly and rearwardly.

15. The payload carrier of claim 14, wherein the shear panel extends in a plane substantially parallel to the surface on which the payload carrier is operably supported.

16. The payload carrier of claim 14, wherein the shear panel is substantially trapezoidal when viewed from the top.

17. The payload carrier of claim 14, wherein the shear panel has a thickness in the range of 2 mm to 6 mm.

18. The payload carrier of claim 17, wherein the shear panel has a thickness of approximately 4 mm.

19. The payload carrier of claim 14, wherein the shear plate is made of metal or a composite material.

20. The payload carrier of claim 14, wherein the shear panels are secured directly or indirectly to the pallet.

21. The payload carrier of claim 2, further comprising at least a first external anchor extending beyond an outer surface of the pallet.

22. The payload carrier of claim 21 , wherein the external anchoring means comprises an outer plate and a back plate, wherein a portion of the external anchoring means extends at least partially through the pallet and between the outer plate and the back plate to sandwich the pallet between the outer plate and the back plate, and wherein The outer panels and / or back panels are bonded to the pallet and wherein the outer anchoring means are made of a metal selected from the list consisting of steel and stainless steel.

23. The payload carrier of claim 21 , wherein the external anchoring device is fixed relative to a support structure.

24. The payload carrier of claim 1, wherein the support subassembly comprises a drive train or chassis subassembly including a set of wheels or a set of tracks.

25. A payload carrier according to claim 24 configured as a hauling vehicle and wherein at least some of the wheels or tracks are driven.

26. The payload carrier of claim 2, wherein the tray shape is one of: U-shaped in cross section, and generally hemispherical.

27. The payload carrier of claim 26, wherein the tray defines a trough portion and a sidewall portion, and wherein a wall thickness of the trough portion exceeds a wall thickness of the sidewall portion, thereby increasing bending stiffness, torsional stiffness, and impact strength of the trough portion.

28. The payload carrier of claim 27, wherein the wall thickness of the side wall portion is in the range of 4 mm to 12 mm.

29. The payload carrier of claim 28, wherein the side wall portion has a wall thickness of approximately 8 mm.

30. The payload carrier of claim 27, wherein the wall thickness of the trough portion is in the range of 8 mm to 20 mm.

31. The payload carrier of claim 30, wherein the wall thickness of the groove portion is approximately 12 mm.

32. The payload carrier of claim 2, wherein the tray is made of a material selected from the list consisting of: Metals including steel and stainless steel; composite materials; A layered material comprising at least one metallic layer and one composite layer.

33. The payload carrier of claim 2, wherein the pallet comprises a plurality of pallet layers, wherein at least one pallet layer is made of a composite material, and wherein the pallet is designed or formed according to an analytically driven design approach.

34. The payload carrier of claim 33, wherein the pallet layer comprises: Main pallet layer; and A liner layer is received on the main tray layer.

35. A payload carrier according to claim 34, wherein the main pallet layer comprises a steel layer or a polymer layer, and wherein the lining layer comprises one of the following: i) a single-piece molded layer; ii) a layer sprayed onto the main pallet layer; iii) a layer cast on the main pallet layer; and iv) a layer composed of adjacent bolted sections, wherein the lining layer comprises a steel layer or a polymer layer, and wherein the polymer layer comprises a fiber-reinforced polymer layer, and the fibers of the fiber-reinforced polymer layer include one of glass fibers, carbon fibers and natural fibers.

36. The payload carrier of claim 34, wherein the operative bottom portion of the main pallet layer comprises a locally thickened wall portion, and wherein the strike plate is optionally sandwiched between the liner layer and the operative bottom portion of the pallet layer.

37. The payload carrier of claim 2, wherein the outer surface of the pallet is lined with a separate protective shield made of a material selected from the list consisting of metals and composite materials, the metals including steel and stainless steel.

38. The payload carrier of claim 1, wherein the integrated tray device has an open top configured to receive a payload therethrough, and wherein the payload is in the form of raw material.

39. The payload carrier of claim 1 , wherein the integrated tray device comprises a measurement sensor for measuring at least one of stress, strain, acceleration, temperature, and vibration, and wherein the measurement sensor comprises one of a strain gauge, an accelerometer, and a thermocouple.

40. The payload carrier of claim 1, wherein the integrated tray device has a roof portion and a closable opening configured as a door.

41. A heavy vehicle comprising a frame formed and designed from composite materials based on an analysis-driven design approach.

42. The heavy vehicle of claim 41 , wherein the frame is made of a polymer material in the form of a fiber-reinforced polymer material, and wherein the fibers comprise one of glass fibers, carbon fibers, and natural fibers.

43. The heavy vehicle of claim 41 wherein the frame comprises an integrally formed lattice structure.

44. A heavy vehicle according to claim 41 , wherein the frame is formed by or with the aid of a moulding process.

45. A heavy vehicle according to claim 44, wherein the frame comprises hollow frame members formed by foam inserts provided in a mould used in a moulding process.

46. ​​The heavy vehicle of claim 41 , wherein the frame includes a measurement sensor for measuring at least one of stress, strain, acceleration, temperature, and vibration applied to or experienced by the frame, and wherein the measurement sensor includes one of a strain gauge, an accelerometer, and a thermocouple.

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