Battery pack module for haulage truck

Abstract

A battery pack module for a haulage truck. A battery pack module for a heavy equipment vehicle (e.g., a mining truck) is presented. The battery pack module may include a plurality of tiers of battery trays, each including a plurality of battery packs. The battery pack module may also include a cooling line system and a battery routing system, each connected in parallel to the battery pack layers. The battery pack module may have a unitary design to reduce weight and manufacturing costs.

Description

Technical Field

[0001] This disclosure generally relates to a battery pack module for hauling trucks (e.g., mining trucks). Specifically, this disclosure relates to a battery pack module comprising a single-cell structure and multiple battery pack layers. Background Technology

[0002] Large equipment vehicles, such as tractor trucks, mining trucks, cranes, bulldozers, etc., may require large power supplies to accommodate the vehicle's workload and / or absolute size. Large equipment vehicles can be equipped with battery packs to increase peak power output during ascent, aid disconnection, recover energy during descent, and otherwise power the engine. Due to the size of large equipment vehicles, a fairly large battery pack system is required to operate them. The large battery pack systems necessary to accommodate the power requirements of operation can be heavy and difficult to install in standard vehicle structures. Summary of the Invention

[0003] This disclosure provides a layered battery pack module configured for installation on a mining truck. The layered battery pack module includes: a support structure including a first support beam and a second support beam, each including a vertical portion and a horizontal portion, the distal end of the vertical portion being coupled to the distal end of the horizontal portion such that an angle is defined between the vertical and horizontal portions; a first side plate coupled to the vertical and horizontal portions of the first support beam; a second side plate coupled to the vertical and horizontal portions of the second support beam, the second side plate being positioned opposite the first side plate; and a plurality of battery pack layers defined between the first and second side plates. In another embodiment, the layered battery pack module further includes a plurality of battery pack trays. Each of the plurality of battery pack trays is removably coupled to a corresponding battery pack layer in the plurality of battery pack layers. In another embodiment, each of the plurality of battery pack trays includes: a battery tray surface; and at least one battery pack coupled to the battery tray surface. Each of the plurality of battery pack trays is configured to slide on a sliding surface of a corresponding battery pack layer in the plurality of battery pack layers. Furthermore, the layered battery pack module includes a first end plate coupled to a distal end of the battery pack surface and a second end plate coupled to a proximal end of the battery pack surface, such that the first and second end plates extend in a direction perpendicular to the battery pack surface. Additionally, each of the plurality of battery pack trays includes three battery packs.

[0004] In another embodiment, the sliding surface of each of the plurality of battery pack layers includes a first support rail connected to and extending the length of a first side plate, and a second support rail connected to and parallel to a second side plate, the second support rail extending the length of the second side plate. Furthermore, each of the plurality of battery pack trays is configured to slide onto the first and second support rails of the corresponding battery pack layer in the plurality of battery pack layers. In yet another embodiment, the layered battery pack tray also includes a top reinforcing tray coupled to the upper portion of each of the first and second side plates. In a different embodiment, the layered battery pack tray further includes: a first mounting pin coupled to a proximal end of a vertical portion of the first support beam; and a second mounting pin coupled to a proximal end of a vertical portion of the second support beam. In another embodiment, the layered battery pack tray also includes a back plate extending between the first and second side plates, the back plate including mounting brackets configured to be coupled to a lower mounting component of a mining truck.

[0005] In another embodiment, the plurality of battery pack layers includes seven battery pack layers. In another embodiment, each of the first side panel and the second side panel includes a bottom mounting surface on the bottom of the first side panel and the second side panel and an upper mounting surface on the upper portion of the first side panel and the second side panel. Furthermore, at least one of a mudguard, a waterproof membrane, and a fluid seal is removably coupled to at least one of the bottom mounting surface and the upper mounting surface. Additionally, the layered battery pack module includes a top mounting surface connected to the top of each of the first side panel, the second side panel, and a back panel extending between the first side panel and the second side panel, the top being located above each of the upper portions of the first side panel and the second side panel and the upper portion of the back panel. The layered battery pack also includes a first service access panel coupled to the first side panel; a second service access panel and a third service access panel coupled to the second side panel; a fourth service access panel coupled to the front panel of the battery pack module; and a fifth service access panel coupled to the top panel of the battery pack module, the top panel being coupled to the top mounting surface. In yet another embodiment, the layered battery pack module has a monolithic design.

[0006] This disclosure further provides a layered battery pack module configured for installation on a mining truck. The layered battery pack module includes: a first side panel corresponding to a first side of the layered battery pack module; a second side panel corresponding to a second side of the layered battery pack module; a plurality of battery pack layers between the first side panel and the second side panel, each of the plurality of battery pack layers defining a sliding surface; and a plurality of battery pack trays, each of the plurality of battery pack trays being configured to be removably received by a corresponding battery pack layer of the plurality of battery pack layers. Each of the plurality of battery pack trays includes: a battery tray surface; and at least one battery pack coupled to the battery tray surface.

[0007] In another embodiment, the layered battery pack module further includes a first end plate coupled to a distal end of the battery tray surface and a second end plate coupled to a proximal end of the battery tray surface, such that the first and second end plates extend in a direction perpendicular to the battery tray surface. Furthermore, each of the first and second end plates includes a tray lifting feature. In another embodiment, the sliding surface of each of the plurality of battery pack layers is defined by: a first support rail coupled to the first side plate and extending the length of the first side plate; and a second support rail coupled to the second side plate and extending the length of the second side plate.

[0008] In another embodiment, each of the plurality of battery pack trays includes a first slide rail configured to be slidably coupled to the first support rail and a second slide rail configured to be slidably coupled to the second support rail. In a different embodiment, each of the plurality of battery pack trays is configured to slide along a sliding surface of the corresponding battery pack layer in a direction away from the chassis of the mining truck. In yet another embodiment, the layered battery pack module further includes a locking mechanism to hold each of the plurality of battery pack trays in position relative to the corresponding battery pack layer.

[0009] In another embodiment, each of the plurality of battery pack trays is configured to slide into one of the plurality of battery pack layers. In yet another embodiment, the plurality of battery pack layers comprises seven battery pack layers. In yet another embodiment, the plurality of battery packs comprises three battery packs. In different embodiments, a first end plate and a second end plate are coupled to the surface of the battery pack such that the mounting lips of the first end plate and the second end plate extend parallel to the surface of the battery pack with respect to a certain distance. In yet another embodiment, each of the plurality of battery pack trays includes two reinforcing ridges, each of the two reinforcing ridges extending the length of the battery pack tray between the distal and proximal ends, wherein the two reinforcing ridges are configured to reduce the bending of the battery pack. In yet another embodiment, the surface of the battery pack includes at least one opening configured to allow fluid to drain through the battery pack tray.

[0010] In another embodiment, the layered battery pack tray further includes a support structure comprising a first support beam and a second support beam, each of the first and second support beams including a vertical portion and a horizontal portion, wherein the distal end of the vertical portion is coupled to the distal end of the horizontal portion to form an angle therebetween. Further, the battery pack tray includes: a first mounting pin coupled to a proximal end of the vertical portion of the first support beam; and a second mounting pin coupled to a proximal end of the vertical portion of the second support beam.

[0011] In another embodiment, the layered battery pack module further includes: a rear panel having a mounting bracket; a first mounting pin engaged with a first side of the layered battery pack module; and a second mounting pin engaged with a second side of the layered battery pack module. Furthermore, the mounting bracket is configured to be engaged with a lower mounting bracket of the mining truck. Additionally, the battery pack module is configured to be mounted to the mining truck via these mounting pins.

[0012] In another embodiment, the layered battery pack module further includes cooling pipelines. The cooling pipelines include: a main cooling supply pipeline fluidly connected to a coolant fluid source; a main return cooling pipeline; and a plurality of battery pack layer cooling pipelines fluidly connected in parallel to the main supply cooling pipeline and the main return cooling pipeline, each of the plurality of battery pack layer cooling pipelines corresponding to one of the plurality of battery pack layers. Furthermore, each of the plurality of battery pack layer cooling pipelines includes: a layer supply pipeline fluidly connected in parallel to a plurality of layer supply branch pipelines, each of the plurality of layer supply branch pipelines corresponding to one of the plurality of battery packs; and a layer return pipeline fluidly connected in parallel to a plurality of layer return branch pipelines, each of the plurality of layer return branch pipelines corresponding to one of the plurality of battery packs. Furthermore, each of the plurality of battery pack layer cooling pipelines includes: a layer supply pipeline fluidly connected in series with a plurality of layer supply branch pipelines, each of the plurality of layer supply branch pipelines corresponding to one of the plurality of battery packs; and a layer return pipeline fluidly connected in series with a plurality of layer return branch pipelines, each of the plurality of layer return branch pipelines corresponding to one of the plurality of battery packs.

[0013] In another embodiment, the layered battery pack module further includes battery cables comprising: a main cable; and a plurality of layer cables electrically connected in parallel to the main cable. Each of the plurality of layer cables corresponds to one of the plurality of battery pack layers. Furthermore, each of the plurality of layer cables corresponds to one of the plurality of battery pack layers and is electrically connected to one of the plurality of battery packs, such that the plurality of battery packs within a common battery pack layer of the plurality of battery pack layers are connected in parallel. In another embodiment, the layered battery pack module has a monolithic design.

[0014] This disclosure also provides a layered battery pack module configured for mounting on a mining truck. The layered battery pack module includes: a first support beam having a first end and a second end; a first plate coupled to the first support beam to form a first sidewall; a second plate coupled to the first support beam to form a rear panel, the second plate including a mounting bracket positioned closer to the second end of the first support beam than the first end, and the mounting bracket being configured to be coupled to a lower mounting member of the vehicle's chassis; and a first pivot pin coupled to the first end of the first support beam but not the second end of the first support beam, and extending from the first end of the first support beam, the first pivot pin being configured to be received by a pin receiving mounting member of the vehicle's chassis. In another embodiment, the layered battery pack module further includes: a second support beam having a first end and a second end, the second support beam being connected to the second plate opposite to the first support beam; a third plate being connected to the second support beam to form a second sidewall; and a second pivot pin being connected to one of the first end of the second support beam and the third plate and extending from one of the first end of the second support beam and the third plate, the third plate being closer to the first end of the second support beam than the second end of the second support beam, the second pivot pin being configured to be received by a pin receiving mount of the chassis of the vehicle.

[0015] In yet another embodiment, the first pivot pin extends in a generally perpendicular direction relative to the first support beam or the first plate. In another embodiment, the mounting bracket is configured to be removably coupled to a lower mounting member of the vehicle's chassis. In yet another embodiment, the lower mounting member to the vehicle's chassis includes vibration damping elements.

[0016] This disclosure also provides a vehicle having a layered battery pack module. The vehicle includes: a first wheel coupled to a first side of a chassis in a first forward position; a second wheel coupled to the first side of the chassis in a first rearward position; a support structure for the battery pack module coupled to the first side of the chassis at a position between the first wheel and the second wheel; and a vertical operating cable extending vertically along at least a portion of the first end of the battery pack module to a first access point. The battery pack module includes a plurality of vertically arranged battery pack layers, each of the plurality of battery pack layers including at least one battery pack. Each of the plurality of battery pack layers includes a tray operating line, each tray operating line being coupled to each battery pack in at least one battery pack of the corresponding battery pack layer, and each tray operating line extending to the first end of the battery pack module. The first access point is located within an access area defined behind the first wheel.

[0017] In another embodiment, each battery pack layer includes multiple battery packs, and each tray operation line connects each of the multiple battery packs in the corresponding battery pack layer in series. In a further embodiment, each battery pack layer includes multiple battery packs, and each tray operation line connects each of the multiple battery packs in the corresponding battery pack layer in parallel. In yet another embodiment, each tray operation line and the vertical operation cable are electronic cables. Furthermore, each tray operation line is connected to the vertical operation cable via a high-voltage electrical interface box.

[0018] In another embodiment, the first access point is a high-voltage electrical box. In yet another embodiment, the first access point is located on the upper mounting surface of the battery pack module. In another embodiment, each tray operating line and vertical operating cable is a cooling line. In yet another embodiment, the access point can be accessed from the access area via a removable service panel of the battery pack module.

[0019] This disclosure provides a battery pack module for a vehicle. The battery pack module includes: a front panel; a rear panel positioned opposite the front panel; a first side panel extending between the front panel and the rear panel, the first side panel having a first service access; and a plurality of battery pack layers vertically arranged within the front panel. The rear panel and the first side panel, each of the plurality of battery pack layers includes a battery pack. Each of the plurality of battery pack layers includes a tray operation line. The tray operation line is removably coupled to the battery pack and is accessible via the first service access for disconnecting the tray operation line from the battery pack. In another embodiment, the service access is one of a door, entrance, or baffle. Further, the battery pack module also includes: a second side panel extending between the front panel and the rear panel opposite to the first side panel; a top panel extending between the front panel, the rear panel, the first side panel, and the second side panel; and a second entrance corresponding to one of the front panel, the rear panel, the second side panel, and the top panel. In another embodiment, the tray operation line extends to a first end of the battery pack module. Additionally, the battery pack module includes a vertical operation cable that extends vertically along at least a portion of the first end of the battery pack module to a third access point.

[0020] In another embodiment, each battery pack layer includes multiple battery packs, and tray operation lines connect each of the multiple battery packs in the corresponding battery pack layer in series. In another embodiment, each battery pack layer includes multiple battery packs, and tray operation lines connect each of the multiple battery packs in the corresponding battery pack layer in parallel.

[0021] In another embodiment, the tray operation line is an electronic cable. In yet another embodiment, the tray operation line includes: a layer supply branch cooling line fluidly connected to the layer supply cooling line, the layer supply cooling line corresponding to a battery pack layer among the plurality of battery pack layers; and a layer return branch cooling line fluidly connected to the layer return cooling line, the layer return cooling line corresponding to a battery pack layer among the plurality of battery pack layers. Furthermore, the battery pack module includes a plurality of battery packs, a plurality of layer supply branch cooling lines, and a plurality of layer return branch cooling lines, such that: each of the plurality of layer supply branch cooling lines corresponds to one battery pack among the plurality of battery packs; each of the plurality of layer return branch cooling lines corresponds to one battery pack among the plurality of battery packs; the layer supply cooling line is fluidly connected to each of the plurality of layer supply branch cooling lines; and the layer return cooling line is fluidly connected to each of the plurality of layer return branch cooling lines. Furthermore, the battery pack module includes: a main cooling supply line fluidly connected to a coolant fluid source and the layer supply cooling line; and a main cooling return line fluidly connected to the layer supply cooling line.

[0022] This disclosure provides a battery pack tray for a layered battery pack module. The battery pack tray includes a tray, a first end plate, and a second end plate. The tray includes a tray surface, a distal end, and a proximal end; a first side and a second side. The tray is configured to support at least one battery pack on the tray surface, the first side including a first sliding surface, and the second side including a second sliding surface. The first end plate is coupled to the distal end of the tray and extends in a direction perpendicular to the tray surface. The second end plate is coupled to the proximal end of the tray. Both the first and second end plates include a reinforcing lip extending parallel to the tray surface from the first and second end plates. In another embodiment, the battery pack tray is configured to slide on the first and second sliding surfaces into the layered battery pack module. In another embodiment, the first sliding surface is defined by a first sliding rail, and the second sliding surface is defined by a second sliding rail. In yet another embodiment, each of the first and second end plates includes a tray lifting opening.

[0023] In another embodiment, the battery pack tray further includes a first reinforcing ridge and a second reinforcing ridge, the first reinforcing ridge extending the length of a first side of the tray between a distal end and a proximal end of the tray, and the second reinforcing ridge extending the length of a second side of the tray between the distal end and the proximal end of the tray. In another embodiment, the tray surface includes a first tray support beam extending between a distal end and a proximal end of the tray, and a second tray support beam extending between a first side and a second side of the tray. Furthermore, the first and second tray support beams define a plurality of tray surface openings configured to allow fluid to drain through the slidable battery pack tray. Additionally, the first and second tray support beams are included in a plurality of tray support beams forming a grid structure on the tray surface.

[0024] In another embodiment, the battery pack tray further includes a cooling line mounting bracket configured to support parallel cooling lines connected to at least one battery pack on the tray surface. In yet another embodiment, the battery pack tray further includes a high-voltage interface box configured to connect to a parallel cable connected to at least one battery pack on the tray surface.

[0025] This disclosure also provides a layered battery pack module for a mining truck. The layered battery pack module includes a plurality of battery pack trays, a coolant piping system, and a battery pack wiring system. Each of the plurality of battery pack trays is removably coupled to a corresponding battery pack layer in a plurality of battery pack layers. Each of the plurality of battery pack trays includes at least one battery pack. The coolant piping system is configured to cool the at least one battery pack. The coolant piping system includes: a main supply cooling line fluidly connected to a coolant fluid source; a main return cooling line; and a plurality of battery pack layer cooling lines fluidly connected to the main supply cooling line and the main return cooling line. Each of the plurality of battery pack layer cooling lines corresponds to one battery pack layer in the plurality of battery pack layers. The battery wiring system is configured to transmit current from the at least one battery pack in each of the plurality of battery pack layers to the mining truck. The battery wiring system includes: a main cable; and a plurality of layer cables electrically connected to the main cable. Each of the multiple layer cables corresponds to one of the multiple battery pack layers.

[0026] In another embodiment, each of the plurality of battery pack layer cooling lines is fluidly connected in parallel to the main supply cooling line and the main return cooling line. In yet another embodiment, each of the plurality of battery pack layer cooling lines is fluidly connected in series with the main supply cooling line and the main return cooling line. In another embodiment, each of the plurality of layer cables is electrically connected in parallel to the main cable. In yet another embodiment, each of the plurality of layer cables is electrically connected in series to the main cable.

[0027] In another embodiment of the battery pack module, each of the plurality of battery pack trays includes: a battery tray surface and a plurality of battery support beams. The tray surface is defined by: a first side; a second side parallel to the first side; a distal end connecting the first side to the second side; and a proximal end connecting the first side to the second side, the proximal end being spaced apart from the distal end by the first side and the second side. The plurality of support beams extend from at least one of: the first side to the second side; and the distal end to the proximal end. Furthermore, at least one battery pack is coupled to at least one of the plurality of battery support beams.

[0028] In another embodiment, each battery pack layer includes a plurality of battery packs, and each of the plurality of battery pack layer cooling pipelines includes: a layer supply pipeline fluidly connected in parallel to a plurality of layer supply branch pipelines, each of the plurality of layer supply branch pipelines corresponding to one of the plurality of battery packs; and a layer return pipeline fluidly connected in parallel to a plurality of layer return branch pipelines, each of the plurality of layer return branch pipelines corresponding to one of the plurality of battery packs.

[0029] In another embodiment, each battery pack layer includes a plurality of battery packs, and each of the plurality of battery pack layer cooling pipelines includes: a layer supply pipeline fluidly connected in series to a plurality of layer supply branch pipelines, each of the plurality of layer supply branch pipelines corresponding to one of the plurality of battery packs; and a layer return pipeline fluidly connected in series to a plurality of layer return branch pipelines, each of the plurality of layer return branch pipelines corresponding to one of the plurality of battery packs. In another embodiment, each battery pack layer includes a plurality of battery packs, and each of the plurality of layer cables is electrically connected in parallel to the plurality of battery packs. In another embodiment, each battery pack layer includes a plurality of battery packs, and each of the plurality of layer cables is electrically connected in series to the plurality of battery packs.

[0030] This invention provides a method for repairing a layered battery pack module on a mining truck. The method includes: removing a first service access panel from a first side of the layered battery pack module; disconnecting battery wiring from the high-voltage electrical interface box of the first battery pack layer, thereby interrupting current flow from any of the battery packs in a plurality of battery packs on the battery pack tray of the first battery pack layer; removing an end service access panel from the front side of the layered battery pack module; and sliding the battery pack tray out of the layered battery pack module. In another embodiment, the method further includes decoupling a tray locking plate from a battery pack tray end plate. In yet another embodiment, the method further includes at least one of: sliding the battery pack tray into the battery pack module; attaching a tray locking plate to the battery pack tray end plate; attaching the end service access panel to the front side of the layered battery pack module; electrically connecting the battery cable to the high-voltage electrical interface box of the first battery pack layer; and attaching the first service access panel to the first side of the layered battery pack module. In yet another embodiment, the method further includes removing a second service access panel from at least one of a second side or a top side of the layered battery pack module. In a further embodiment, sliding the battery pack tray out of the layered battery pack module includes: inserting a tool into a lifting feature on the distal end of the battery pack tray; and using the tool to slide the battery pack tray out of the battery pack module. Attached Figure Description

[0031] The above and other features and advantages of this disclosure, and the ways in which they are obtained, will become more apparent and better understood from the following description of exemplary embodiments taken in conjunction with the accompanying drawings, wherein:

[0032] Figure 1 It is a schematic top-down diagram of the structural layout of the components of a mining truck;

[0033] Figure 2 A schematic top-down diagram showing the structural arrangement of components of a mining truck;

[0034] Figure 3 A top-down schematic diagram of a battery pack module relative to the chassis and multiple wheels of a mining truck is shown, wherein the multiple wheels are in a first configuration;

[0035] Figure 4 It shows Figure 3 A top-down schematic diagram of the battery pack module, in which the multiple wheels are in a second configuration;

[0036] Figure 5 This is a perspective view of the support structure of the battery pack module disclosed herein;

[0037] Figure 6AThis is a perspective view of the side panel, support structure, and support plate of the battery pack module disclosed herein;

[0038] Figure 6B yes Figure 6A The perspective view of the battery pack module also includes the support rail, upper mounting surface, top cover mounting surface and bottom mounting surface;

[0039] Figure 7A This is a perspective view of the locking plate of the battery pack module disclosed herein;

[0040] Figure 7B yes Figure 7A A perspective view of the battery pack module, in which the locking plate has been removed and the battery tray has been removed from the battery pack module;

[0041] Figure 8A This is a top perspective view of the battery tray disclosed herein;

[0042] Figure 8B yes Figure 8A Bottom perspective view of the battery tray;

[0043] Figure 8C yes Figures 8A to 8B A close-up end view of the battery tray;

[0044] Figure 9 This is a first perspective view of the exposed first side of the battery pack module disclosed herein;

[0045] Figure 10 yes Figure 9 A second perspective view of the exposed first side of the battery pack module;

[0046] Figure 11A This is a perspective view of the first side of the battery pack module disclosed herein;

[0047] Figure 11B yes Figure 11A A perspective view of the second side of the battery pack module; and

[0048] Figure 11C yes Figures 11A to 11B A perspective view of the third side of the battery pack module.

[0049] In these views, corresponding reference numerals denote corresponding parts. Although the drawings illustrate embodiments of various features and components according to this disclosure, the drawings are not necessarily to scale, and certain features may be exaggerated to better illustrate and explain this disclosure. The examples presented herein illustrate embodiments of this disclosure, and such examples should not be construed as limiting the scope of this disclosure in any way. Detailed Implementation

[0050] To facilitate understanding of the principles of this disclosure, reference is now made to embodiments illustrated in the accompanying drawings, which are described below. The exemplary embodiments disclosed herein are not intended to be exhaustive or to limit this disclosure to the precise forms disclosed in the following detailed description. Rather, these exemplary embodiments have been chosen and described so that others skilled in the art can utilize their teachings.

[0051] The terms “connection,” “connected,” “connector,” and variations thereof are used to include arrangements in which two or more components are in direct physical contact with each other and arrangements in which two or more components are not in direct contact with each other (e.g., the components are “connected” via at least a third component) but still cooperate or interact with each other.

[0052] Throughout this disclosure and in some instances of the claims, numerical terms such as first, second, third, fourth, etc., are used to refer to various components of the feature. This use is not intended to indicate an order of these components or features. Rather, numerical terms are used to help the reader identify the referenced components or features and should not be interpreted narrowly as providing a specific order of components or features.

[0053] Although the information disclosed herein is provided in the form of “mining trucks,” it should be understood that the features described herein can be applied to other vehicles, including heavy equipment such as cranes, bulldozers, excavators, locomotives, and other suitable vehicles.

[0054] The schematic structure of the example mining truck 100 is shown in Figure 1 As shown in the figure, a mining truck 100 can typically be built on and / or around a chassis 102. The chassis 102 may include a first frame member 104 and a second frame member 106 extending longitudinally from a first end of the chassis including a first end to a second end of the chassis including a second end, to at least partially define the length of the mining truck 100. The first frame member 104 and the second frame member 106 may be spaced apart to form a space 108 therebetween, wherein a central crossbeam 110 extends from the first frame member 104 to the second frame member 106 across the space 108, generally defining a rear chassis region 112. A rear crossbeam 114 may extend from the first frame member 104 to the second frame member 106 across the space 108 at the rear of the chassis 102, and a yoke 116 may connect the first frame member 104 and the second frame member 106 within a front region 118 of the chassis 102.

[0055] The third frame member 120 may extend through the top of the yoke 116 and beyond the diameter of the yoke 116 to form a frame for the deck 122. Figure 1The first supplementary frame member 124 and the second supplementary frame member 126 may each extend diagonally in opposite directions above the yoke 116 from the center portion 128 of the third frame member 120, such that the first supplementary frame member 124 can be connected to the first support plate 130, and the second supplementary frame member 126 can be connected to the second support plate 134. The first support plate 130 may also be connected to the first frame member 104 on a first side 132 of the chassis 102, and the second support plate 134 may also be connected to the second frame member 106 on a second side 136 of the chassis 102.

[0056] A front crossbeam 138 may extend from the first frame member 104 to the second frame member 106, substantially aligned with the first support plate 130 and the second support plate 134. A support extension 140 may extend forward of the front crossbeam 138. An engine 142 may be positioned within an opening 144 defined by a yoke 116. A traction alternator and / or gearbox may be mounted within region 164 behind the engine 142.

[0057] Wheels 146, 148, 150, and 152 can be mounted to chassis 102 via their respective axles (not shown). For example, as shown, the first wheel 146 can be mounted in a forward position in the front region 118 of the first side 132 of chassis 102. The second wheel 148 can be mounted in a rearward position in the rear region 112 of the first side 132 of chassis 102. The third wheel 150 can be mounted in a forward position in the front region 118 of the second side 136 of chassis 102. The fourth wheel 152 can be mounted in a rearward position in the rear region 112 of the second side 136 of chassis 102. In some embodiments, the mining truck 100 may include a fifth wheel 154 mounted adjacent to the second wheel 148 in a rearward position in the rear region 112 of the first side 132 of chassis 102. Some embodiments may additionally include a sixth wheel 156 mounted rearward in a rearward position adjacent to the fourth wheel 152 in the rear region 112 on the second side 136 of the chassis 102. The first wheel 146 and the third wheel 150 may be mounted in positions generally corresponding to the third frame member 102.

[0058] The dimensions and shape of the rear area space 158, defined within the rear chassis region 112 between the first frame member 104 and the second frame member 106, and at least partially defined between the second wheel 148 and the fourth wheel 152, can be determined for receiving the vehicle subsystem 160. For example, as Figure 1As shown, vehicle subsystem 160 may include after-treatment system 162. In other embodiments, vehicle subsystem 160 may include a battery module, fuel tank, powertrain support subsystem, exhaust muffler, exhaust silencer, or any other vehicle subsystem necessary for or otherwise desired for the operation of mining truck 100. As described herein, exhaust mufflers and exhaust silencers may be similar or identical components used to silence exhaust gases within a certain volume. In other embodiments, the rear area space 158 may not contain any vehicle subsystems or components.

[0059] For further reference Figure 2 As described above, deck 122 can be supported by chassis 102 in a forward position. Deck 122 may include a first region 188 associated with a first side of deck 122 and a second region 190 associated with a second side of deck 122, wherein the first side of deck 122 corresponds to a first side 132 of chassis 102 and the second side of deck 122 corresponds to a second side 136 of chassis 102. The first region 188 and the second region 190 are indicated by a dividing line “D”. An operator’s cab 192 may be arranged within the second region 190 of deck 122. The operator’s cab 192 is configured to accommodate an operator during operation of the mining truck 100, as well as necessary or desired control devices for said operation of the mining truck 100.

[0060] Resistor gate 194 may be disposed within a first region 188 of deck 122 and may be positioned substantially rearward of the first region 188 of deck 122. DC / DC system 196 may be positioned on top of resistor gate 194 such that DC / DC system 196 and resistor gate 194 are in a vertically stacked arrangement. In other embodiments, DC / DC system 196 may be positioned forward relative to resistor gate 194.

[0061] Inverter cabinet 198 may be located at least partially in a first region 188 of deck 122 and at least partially in a second region 190 of deck 122. For example, inverter cabinet 198 may be equivalently located in the first region 188 and the second region 190, or in some embodiments, it may be positioned such that the majority of inverter cabinet 198 is located in the first region 188. In other embodiments, inverter cabinet 198 may be positioned such that the majority of inverter cabinet 198 is located in the second region 190. As shown, inverter cabinet 198 may be located within the rear portion of deck 122. For example, positioning inverter cabinet 198 in this manner may provide an open area for accommodating additional mining truck components.

[0062] The mining truck 100 may also include a thermal management system 200. The thermal management system 200 may include a radiator 202 and a DC / DC battery thermal manager 204. In some embodiments, the radiator 202 and the DC / DC battery thermal manager 204 may be integrated, i.e., a single thermal management component may serve as both the radiator 202 and the DC / DC battery thermal manager 204. In other embodiments, the radiator 202 may serve both the engine 142 and the DC / DC system 196, while the battery thermal manager 204 serves only the battery pack module 176, as further described herein. In other embodiments, the radiator 202 may serve the engine 142, the battery thermal manager 204 may serve the battery pack module 176, and a third thermal manager or heat exchanger (not shown) may serve the DC / DC system 196.

[0063] As shown, the radiator 202 can be mounted at the front of the mining truck 100, or in other words, in a fully forward position relative to the deck 122. For example, the radiator can be mounted at a first end 102, adjacent to a first end of the chassis 102. In some embodiments, the radiator 202 can be at least partially mounted to the leading edge of the deck 122, such that the radiator 202 extends downward from the deck 122. In other embodiments, the radiator 202 can be mounted below the deck 122 at the front of the mining truck 100. In yet another embodiment, the radiator 202 can be mounted at another location on the mining truck 100.

[0064] The DC / DC battery thermal manager 204 may be positioned on deck 122 within a first region 188, at a forward position of resistor grid 194 and / or DC / DC system 196. As further described herein, the DC / DC battery thermal manager 204 may be configured to be fluidly coupled to battery pack module 176 to provide coolant or cryogenic fluid to battery pack module 176, and in some embodiments, fluidly coupled to DC / DC system 196 to provide thermal management services to DC / DC system 196.

[0065] The arrangement of components on the deck described herein is exemplary in nature and may be modified within the scope of this disclosure. For example, in some embodiments, the first region 188 and the second region 190 may be mirrored or switched. In other embodiments, components may be movable relative to each other and / or relative to deck 122. The positioning of components on the deck as described herein can mitigate damage and / or poor performance from dust, dirt, mud, and / or other environmental considerations. However, other arrangements are also within the scope of this disclosure.

[0066] Refer again Figure 1First wheel 146 and second wheel 148 may define a space or a first side saddle 166 between them. In some embodiments, as shown, fuel tank 168 may be mounted on chassis 102 within the first side saddle 166. Fuel tank 168 may contain, for example, diesel fuel or alternative fuels such as ammonia, methanol, ethanol, or other fuels suitable for the operation of mining truck 100. Similarly, third wheel 150 and fourth wheel 152 may define a space or a second side saddle 170. First wheel motor 172 may be associated with second wheel 148, and in embodiments including a fifth wheel, with fifth wheel 154. Second wheel motor 174 may be associated with fourth wheel 152, and in embodiments including a sixth wheel, with sixth wheel 156. In some embodiments including a fifth and / or sixth wheel, each of second wheel 148, fourth wheel 152, fifth wheel 154, and sixth wheel 156 may have a separate wheel motor. In other embodiments, all wheels 146, 148, 150, 152, 154 and 156 or wheels 146, 148, 150, 152 or any combination thereof may be associated with a wheel motor, whether such wheel motor is specified as a single wheel or such wheel motor is shared between two or more wheels.

[0067] Mining truck 100 may include, for example Figure 2 The battery pack module 176 is shown. For example, as further discussed above, the mining truck 100 may include a first wheel 146 mounted in a forward position (i.e., adjacent to the first frame member 104) in a front region 118 on a first side 132 of the chassis 102, and a second wheel 148 mounted in a rearward position (i.e., adjacent to the first frame member 104) in a rear region 112 on the first side 132 of the chassis 102. The first wheel 146 and the second wheel 148 may be spaced apart to define a first side saddle 166 between them. As shown, the battery pack module 176 may be mounted within the first side saddle 166 to the first side 132 of the chassis 102. In other embodiments, the battery pack module 176 may be mounted to the chassis 102 or another component of the mining truck 100.

[0068] Battery module 176 can be configured to store electricity used in the operation of mining truck 100. In hybrid applications, battery module 176 can cooperate with engine 142 to provide power to wheels 146, 148, 150, 152, and in some embodiments, to wheels 154, 156 for movement of mining truck 100. Battery module 176 can be mounted within a first side saddle 166 at a location that reduces potential contact between any of wheels 146, 148, 150, 152, 154 (when present) and / or 156 (when present).

[0069] For example, such as Figures 3 to 4As shown, the battery module 176 can be mounted to the chassis 102 in a manner defined by a front access area 178 between the first wheel 146 and the battery module 176, and a rear access area 180 between the battery module 176 and the second wheel 148. The front access area 178 and the rear access area 180 provide clearance for wheel movement during operation of the mining truck, and also provide clearance for the operator, mechanic, or other person to stand within the appropriate access areas 178, 180 for accessing the battery module 176 for maintenance or other required or desired tasks.

[0070] The steering area or additional access area 182 may be defined adjacent to the front recess to ensure additional clearance for steering of the first wheel 146 during operation of the mining truck 100, such as... Figure 4 As shown in the diagram. The additional access area 182 may also provide additional clearance for an operator, technician, or another person to access the battery pack module 176 for maintenance or other required or desired tasks. For example, in some embodiments, the battery pack module 176 may be mounted to the mining truck 100 in such a manner that access to the battery pack module 176 is typically located in or adjacent to the additional access area 182.

[0071] Refer again Figure 2 A hydraulic fluid tank 184 may be mounted on the second side 136 of the chassis 102 within the second side saddle 170. The hydraulic fluid tank 184 serves as a reservoir for holding excess hydraulic fluid used in the operation of the mining truck 100. A second fluid tank 186 may be mounted on the chassis 102 within the second side saddle 170. In some embodiments, the second fluid tank 186 may be a fuel tank.

[0072] As shown in the figure, hydraulic fluid tank 184 can be mounted to chassis 102 at an internal location within the second side saddle 170, while a second fluid tank 186 can be mounted to chassis 102 at an external location within the second side saddle 170, such that hydraulic fluid tank 184 is substantially located between chassis 102 and the second fluid tank 186. In other embodiments, hydraulic fluid tank 184 and the second fluid tank 186 can be arranged alternately. For example, in some embodiments, the second fluid tank 186 can be mounted to chassis 102 at an internal location within the second side saddle 170, while hydraulic fluid tank 184 can be mounted to chassis 102 at an external location within the second side saddle 170. In still other embodiments, both hydraulic fluid tank 184 and the second fluid tank 186 can be arranged substantially internally within the second side saddle 170, such that one of hydraulic fluid tank 184 and the second fluid tank 186 is positioned in a forward position near the third wheel 150, while the other of hydraulic fluid tank 184 and the second fluid tank 186 is positioned in a rearward position near the fourth wheel 152.

[0073] In some embodiments, a third liquid tank (e.g., a second fuel tank) may be mounted on the chassis 102 within the second side saddle 170. In other embodiments, the second fuel tank may be mounted in series with the battery pack module 176 on the chassis 102 within the first side saddle 166.

[0074] While the above embodiments include mounting the battery pack module 176 within the first side saddle 166 and the hydraulic fluid tank 184 and the second fluid tank 186 within the second side saddle 170, other arrangements are also conceivable, which also enjoy at least some of the advantages described above. For example, in some embodiments, the battery pack module 176 may be mounted within the second side saddle 170 adjacent to the hydraulic fluid tank 184, while the second fluid tank 186 is mounted on the chassis 102 within the first side saddle 166. In other embodiments, the hydraulic fluid tank 184 may be held within the second side saddle 170, the second fluid tank 186 may be mounted within the first side saddle 166 onto the chassis 102, and the battery pack module 176 may be mounted onto the deck 122.

[0075] When one or more boxes are also mounted on the chassis 102 defined within a second side saddle 170 between the third wheel 150 and the fourth wheel 152, the mounting of the battery pack module 176 within the first side saddle 166 can contribute to the balance of the mining truck 100. This arrangement also maximizes the space available for battery positioning, while allowing the batteries to be placed in a single, uniform space, rather than distributed across several locations on the structure of the mining truck 100. For example, in some embodiments and as further described herein, the battery pack module 176 may include multiple battery pack layers in a vertical arrangement, wherein each of the multiple battery pack layers includes one or more battery packs. This vertical arrangement of the battery packs positioned in the side saddles can take advantage of the height of the mining truck 100 to include as many battery packs as possible required for the effective operation of the mining truck 100 in hybrid operating modes. While these benefits are acknowledged, battery module 176 and / or multiple battery packs may be alternately located in a single, uniform space (i.e., on deck 122, within rear area space 158, or another location), or in multiple locations throughout the structure of the mining truck 100, which is also within the scope of this disclosure.

[0076] refer to Figures 5 to 7BThe image illustrates a battery pack module 176 of this disclosure. The battery pack module 176 may include a single-unit design. As used herein, "single-unit" describes a module in which multiple individual components of the module are brought together to form an entire module, in this case, forming the battery pack module 176. In some embodiments, for example, the individual components constituting the single-unit of the battery pack module may be individual components assembled to form the single-unit design. When these components are assembled together, the battery pack module 176 is further strengthened by adding more components. The single-unit design allows the battery pack module to be manufactured lighter and cheaper than conventional battery modules. The battery pack module 176 may not include a frame, but may be made from each of the following components joined together. However, in alternative embodiments, the battery pack module 176 may include a frame.

[0077] First refer to Figure 5 The support structure 240 for the battery module 176 may include a first support beam 242a and a second support beam 242b. In one embodiment, the support beams 242a and 242b may be shaped to accommodate forklift forks to facilitate mounting the battery module 176 onto the mining truck 100. For example, the support beams 242a and 242b may be spaced apart by a distance consistent with the spacing of the forklift forks. In other embodiments, other lifting mechanisms consistent with the shape and size of the support beams 242a and 242b may be used to facilitate mounting the battery module 176 onto the mining truck 100. In some embodiments, the shape and size of the support beams 242a and 242b may be modified to accommodate alternative lifting mechanisms known in the art. In other embodiments, the support beams 242a and 242b may be generally shaped to accommodate multiple lifting mechanisms and / or lifting mechanisms that do not require a specific shape and / or size may be used to facilitate mounting the battery module 176 onto the mining truck 100. In other embodiments, the battery module 176 can be manually mounted onto the mining truck 100, eliminating the need for a lifting mechanism and / or support beams 242a, 242b with specific shapes.

[0078] Support beams 242a and 242b may each include vertical portions 244a and 244b and horizontal portions 246a and 246b. Horizontal portions 246a and 246b may each include an opening 247, the size and shape of which are determined for receiving forklift forks or another lifting component of another lifting mechanism. For example, the opening 247 may form a recess within the horizontal portions 246a and 246b, and / or may open towards the bottom of the horizontal portions 246a and 246b to facilitate receiving forklift forks or other lifting tools. Support beams 242a and 242b may be L-shaped or any other shape, such as C-shaped, which suitably accommodates lifting devices to mount the battery module 176 within the side saddle 166 of the mining truck 100. As described above, in some embodiments, the support beams 242a, 242b may be otherwise sized and / or shaped to facilitate cooperation with other lifting mechanisms, or in other embodiments, the support beams 242a, 242b may have an overall size and shape common to multiple lifting mechanisms or not specific to any lifting mechanism. Accordingly, in some embodiments, the horizontal portions 246a, 246b may not include any openings or recesses.

[0079] The distal end of the vertical portion 244a may meet the distal end of the horizontal portion 246a, thereby forming a connection point 248a. Similarly, the distal end of the vertical portion 244b may meet the distal end of the horizontal portion 246b, thereby forming a connection point 248b. Each vertical portion 244a, 244b may be connected to its corresponding horizontal portion 246a, 246b using any connection mechanism known in the art. For example, each vertical portion 244a, 244b may be connected to its corresponding horizontal portion 246a, 246b via welding, adhesive, mechanical fasteners, interference fit, locking mechanism, coupling mechanism, or any other connection mechanism that facilitates the operation and use of the battery pack module 176 as described herein. In some embodiments, each vertical portion 244a, 244b may be formed as a single piece with its corresponding horizontal portion 246a, 246b by, for example, additional printing, casting, molding, or other manufacturing methods known in the art. In other embodiments, the support structure 240 may consist only of the horizontal portions 246a, 246b of the first and second support beams 242a, 242b.

[0080] Although the support structure 240 is described above as including two support beams 242a, 242b, in some embodiments, the support structure 240 may include fewer support beams (i.e., one or none) or more support beams. In some embodiments, the included plurality of support beams may be positioned in various arrangements consistent with the environment and use of the battery pack module 176 as discussed herein. For example, in some embodiments, the support structure 240 may include four support beams similar to the support beams 242a, 242b as described above, wherein the support beams are arranged such that two vertical beams extend between two horizontal beams to create two square or rectangular structures, for example, such that the combination of all four support beams creates a prism or cube shape, which may or may not include a crossbeam between the two square or rectangular structures. Other embodiments may include alternatively arranged support beams.

[0081] The battery pack module 176 can be removably coupled to the mining truck 100 via at least one top mount and a lower mount (not shown). The top mount may include a mounting mechanism coupled to the battery pack module 176; for example, the top mount may be positioned on the rear panel 208. Figure 7B The top mount may be positioned on or located on support beams 242a, 242b, as further discussed herein. In some embodiments, the top mount may include a mounting mechanism coupled to the chassis 102 of the mining truck 100. In such embodiments including a top mount coupled to the chassis 102 of the mining truck 100, the battery pack module 176 may include a top mounting bracket configured to be removably coupled to the at least one top mount. The top mount may be fixedly coupled and / or integrated with the underlying battery pack module 176, chassis 102, or other mining truck components to facilitate structural integrity for mounting the battery pack module 176. In other embodiments, the top mount may be otherwise removably coupled to the underlying battery pack module 176, chassis 102, or other mining truck components.

[0082] In some embodiments, the battery pack module 176 may include two top mounts for connecting the battery pack module 176 to the chassis 102. For example, the two top mounts may include a first chassis mounting pin 230a fixed to the top portion / proximal end 245a of the vertical portion 244a of the first support beam 242a, and a second chassis mounting pin 230b fixed to the top portion / proximal end 245b of the vertical portion 244b of the second support beam 242b. Each of the chassis mounting pins 230a and 230b may extend outward from its respective support beam 242a, 242b, i.e., in a direction away from the other support beam. In some embodiments, for example, the chassis mounting pins 230a, 230b may extend in opposite directions. In some embodiments, the chassis mounting pins 230a, 230b may each extend in a direction substantially perpendicular to their corresponding support beam 242a, 242b.

[0083] Chassis mounting pins 230a and 230b can each be configured to be received by one or more pin-receiving mounts (not shown) on the chassis 102 or another component of the mining truck 100. Alternatively, chassis mounting pins 230a and 230b can be attached to the top of side panels 302a and 302b. Figures 6A to 6B This will be discussed further below.

[0084] See brief Figure 11B The battery module 176 may include a mounting bracket 219 positioned on the rear panel 208, or another panel of the battery module 176 as further described herein, the mounting bracket 219 being configured to be coupled to a lower mount of the mining truck 100 as discussed above. The lower mount (not shown) may be coupled to, integral with, and / or extend from the chassis 102 of the mining truck 100, and removably coupled to the mounting bracket 219. In some embodiments, the lower mount may include or be coupled to a damping element, such as a rubber disc, spring, torsion bar, airbag damper, or another damping element. The lower mount may be removably coupled to the mounting bracket 219 such that vibrations transmitted from the mining truck to the battery module 176 are reduced. In various embodiments, in addition to or in lieu of the top mounting (e.g., chassis mounting pins 230a, 230b), mounting brackets 219 and / or lower mounting members may be included.

[0085] Now for reference Figure 6A and Figure 6BThe battery module 176 may include a first side plate 302a and a second side plate 302b connected to the support structure 240. For example, the bottom 303 of each side plate 302a, 302b may be attached to the length of the horizontal portions 246a, 246b of the corresponding support beams 242a, 242b, for example, side plate 302a corresponding to support beam 242a and side plate 302b corresponding to support beam 242b. The side portion 305 of each side plate 302a, 302b may be attached to the length of the vertical portions 244a, 244b of the corresponding support beams 242a, 242b. In some embodiments, the side plates 302a, 302b may be formed of sheet metal. In some embodiments, for example, the side plates 302a, 302b may be formed of aluminum, brass, copper, steel, tin, nickel, titanium, silver, gold, platinum, or other metals suitable for the environment surrounding the mining truck 100 and / or for the use of the battery module 176. In other embodiments, the side panels 302a, 302b may be formed of polymers or other suitable materials, as discussed further herein.

[0086] Each side panel 302a, 302b includes a plurality of support rails 310 extending along the length of the corresponding side panel 302a, 302b. For example, the support rails 310 may extend horizontally, and in some embodiments, extend generally parallel to the horizontal portions 246a, 246b of the first and second support beams 242a, 242b. The support rails 310a of side panel 302a and 310b of side panel 302b are at similar heights, such that the support rails 310a and 310b can cooperate to form layered pairs of support rails 310, with a pair of support rails 310 at each layer height to define a plurality of battery pack layers 500. Figure 8A , Figure 8B (as discussed further in this article).

[0087] Each pair of support rails 310 is configured to receive a battery tray, as further discussed below. For example, each support rail 310a, 310b may define a sliding surface such that each battery tray slides onto the corresponding pair of support rails to be received within the battery pack module 176. The support rails 310 may be U-shaped channel rails, L-shaped bracket rails, or other rails that provide a sliding surface for receiving the battery tray, as further described herein.

[0088] Battery module 176 may include a support plate 304 to support battery module 176 and promote the structural integrity of battery module 176 by providing further support. For example, as shown, support plate 304 may include a beam extending between the vertical portions 244a, 244b and / or the horizontal portions 246a, 246b of the first and second support beams 242a, 242b.

[0089] See also Figures 6A to 6BThe side panels 302a, 302b and / or the support plate 304 may include an upper mounting surface 312 configured to receive a reinforcing tray 406. Figure 8A and Figure 8B This is to strengthen and reduce the bending of the side plates 302a, 302b. The upper mounting surface 312 may extend in circumference between the vertical portions 244a, 244b of the first and second support beams at the top 306 of the side plates 302a, 302b and / or the support plate 304. The upper mounting surface 312 may consist of a support rail similar to the support rail 310 or another rail or support surface connected to the upper part of the side plates 302a, 302b and / or the support plate 304. In other embodiments, the upper mounting surface 312 may be integrally formed with the side plates 302a, 302b and / or the support plate 304.

[0090] Side panels 302a, 302b and support plate 304 may also include a top cover mounting surface 314 configured to allow connection of the fifth service access panel / top cover 228. Figures 11A to 11C The top cover mounting surface 314 may extend the outer periphery of the side plates 302a, 302b and / or support plate 304 above the upper mounting surface 312 between the vertical portions 244a, 244b of the first and second support beams 242a, 242b. The top cover mounting surface 314 may be a rail similar to support rail 310, or another rail coupled to the top of the side plates 302a, 302b and / or support plate 304. In other embodiments, the top cover mounting surface 314 may be an integral extension of the side plates 302a, 302b and / or support plate 304. In other embodiments, the top cover mounting surface 314 may be any flat surface of the side plates 302a, 302b and / or support plate 304 corresponding to the top of the side plates 302a, 302b and / or support plate 304. In some embodiments, the structure of the top cover mounting surface 314 may vary among the side plates 302a, 302b and / or support plate 304.

[0091] Side panels 302a, 302b and / or support plate 304 may include a bottom mounting surface 316 between the vertical portions 244a, 244b of the first and second support beams, along the lower periphery of the side panels 302a, 302b and / or support plate 304. Mudguards, waterproof plates, mounting covers, fluid seals and other protective components may be coupled to the bottom mounting surface 316 and the upper mounting surface 312 to protect the battery pack module 176 from external elements and fluids. For example, mounting covers, mudguards, mounting shields, etc., may be coupled to the upper mounting surface 312 and the bottom mounting surface 316 in such a way that the sides of the battery pack module 176, such as the side panels 302a, 302b, support plate 304 and / or end locking plate 404 discussed further below, are substantially or completely covered by the protective components. In some embodiments, the protective components may also be coupled to the battery pack module at one or more connection points between the upper mounting surface 312 and the bottom mounting surface 316.

[0092] Figure 7A and Figure 7B The internal structure and components of battery pack module 176 are shown. For example, battery pack module 176 includes at least one battery pack layer 500, and may include multiple battery pack layers 500. In some embodiments, as shown, battery pack module 176 includes seven battery pack layers 500. In other embodiments, battery pack module 176 may include more or fewer battery pack layers 500, including 1, 2, 3, 4, 5, 6, 8, 9, 10, 11, 12, 13, 14, 15, or more, which are suitable for the application of battery pack module 176 and / or available space for mounting battery pack module 176.

[0093] Each battery pack layer 500 may include at least one battery tray 502, on which one or more battery packs 504 are located. For example, one or more battery packs 504 may be removably attached to each battery tray 502. The shape and size of the battery tray 502 may be configured to have a width only slightly narrower than the width between the side panels 302a, 302b.

[0094] Battery tray 502 can be configured to slide on support rail 310 (i.e., the sliding surface of the corresponding support rail 310), such that battery tray 502 is positioned vertically in accordance with the arrangement of battery pack layer 500. Each battery tray 502 can be removed from battery module 176 independently of other battery trays 502. For example, each battery tray 502 can slide independently along the corresponding sliding surface of the corresponding support rail 310. In some embodiments, battery tray 502 can be removed remotely from mining truck 100 ( Figure 1The battery tray 502 is removed by sliding out of the battery module 176 in the direction of the chassis 102. Removal of the battery tray 502 facilitates access to the battery pack 504 for maintenance, replacement or other purposes.

[0095] To maintain the position of each battery tray 502 within its corresponding battery pack layer 500, each battery pack layer 500 may include two side locking plates 402. For example, each battery pack layer 500 may include a side locking plate positioned on either side of the battery pack layer 500, such that each side locking plate 402 is coupled to one of the side plates 302a, 302b (in Figure 7A As shown relative to 302a, however, it should be understood that the arrangement of the side locking plate is the same or similar to that of the side plate 302b.

[0096] The side locking plate 402 can hold or lock the battery tray 502 within the corresponding battery pack layer 500 to mitigate or prevent movement of the battery tray 502 and / or other unintentional movement during operation of the mining truck 100.

[0097] Each battery tray 502 can also be held within the corresponding battery pack layer 500 by an end locking plate 404. The end locking plate 404 may extend between and / or be removably coupled to the first side plate 302a and the second side plate 302b. The end locking plate 404 may extend vertically such that it at least partially covers each battery pack layer 500, and thereby covers each battery tray 502, to mitigate or prevent accidental slippage of the battery pack layer battery tray 502 from the battery pack module 176. In some embodiments, the end locking plate 404 may be additionally or alternatively removably coupled to the end 514 of at least one battery tray 502 opposite the support structure 240. In some embodiments, the end locking plate 404 may be removably coupled to a plurality of battery trays 502 or all of the battery trays 502.

[0098] While the side locking plate 402 and end locking plate 404 can be used to hold or lock the battery tray 502 in place relative to the battery pack layer 500, other embodiments may include other or alternative locking mechanisms to hold the battery tray 502 in place relative to the battery pack layer 500. For example, in some embodiments, the battery tray 502 may be bolted to the battery pack layer 500 to hold the battery tray 502 in place while maintaining the removable feature of the battery tray 502. In other embodiments, other locking mechanisms may be considered, including in-slot inserts, clips, removable adhesives, magnets, or other locking mechanisms known in the art. Such locking mechanisms may be used in conjunction with, or alternatively in conjunction with, the side end plate 402 and end locking plate 404.

[0099] Figures 8A to 8C Battery tray 502 is further illustrated. Each battery tray 502 may be substantially similar to the other battery trays 502 of battery pack module 176. Thus, although individual battery trays are discussed below, the features and characteristics discussed herein generally apply to each battery tray 502 of battery pack module 176.

[0100] The battery tray 502 may include a tray surface 506 and an outer frame 510 surrounding the outer periphery of the tray surface 506. The outer periphery of the tray surface 506 may include a first side 518a, a first end 514, a second side 518b, and a second end 516, wherein the first side 518a and the second side 518b may each have a length 518, and the first end 514 and the second end 516 are spaced apart by a length 518.

[0101] End plate 520 can be attached to each of the first end 514 and the second end 516. End plates 520 can be configured such that a mounting lip 521 extends from the end plate 520 on the first end 514 and / or the second end 516 to the underside of the tray surface 506, for example, to the battery support beam 508, as discussed further herein. The mounting lip 521 can provide stability and structural integrity to the tray during lifting, installation, and removal from the battery pack module 176.

[0102] The end plate 520 may also include a tray lifting feature 522 configured to allow the battery tray 502 to be gripped and slid out from a corresponding battery pack layer 500 on the support rail 310. In one embodiment, the tray lifting feature 522 may be a hole configured to receive a tool or finger, for example, to facilitate applying force to the battery tray 502 to remove the battery tray 502 from the battery pack layer 500. In some embodiments, the end plate 520 and / or mounting lip 521 may be manufactured separately and later coupled to the battery tray 502. In other embodiments, the end plate 520 and / or mounting lip 521 may be integrally formed with the battery tray 502.

[0103] Now for reference Figure 9 The tray surface 506 may include a plurality of battery support beams 508. Each battery support beam 508 may extend between a first side 518a and a second side 518b of the outer frame 510 and / or between a first end 514 and a second end 516 of the outer frame 510, such that a tray opening 512 is defined therebetween. The battery support beams 508 are configured to support one or more battery packs 504 on the tray surface 506. For example, in some embodiments, each battery pack 504 may be removably coupled to one or more battery support beams 508. In one embodiment, the battery support beams 508 may form a mesh structure.

[0104] The tray opening 512 allows fluid to drain through each battery tray 502. For example, the tray opening 512 may allow liquid fluid to flow from the battery pack layer 500 toward the bottom mounting surface 316 of the battery pack module 176. In addition, the tray opening 512 allows air to circulate through the multiple battery pack layers 500, thereby facilitating temperature control of the battery pack 504 by cooling the battery pack 504 on each battery tray 502.

[0105] Each battery tray 502 can support multiple battery packs 504. For example, each battery tray 502 may have multiple battery packs 504 removably attached thereto (i.e., attached to the tray surface 506 and / or the battery support beam 508). In one embodiment, each battery tray 502 may include three battery packs 504. In other embodiments, more or fewer battery packs 504 may be included, such as 1, 2, 4, 5, 6, 7, 8, 9, 10 or more battery packs, because the battery tray 502 is capable of supporting them.

[0106] See now Figure 9 A reinforcing ridge 524 may extend at least a portion of each of the first side 518a and the second side 518b of the battery tray 502. The reinforcing ridge 524 is configured to reinforce the battery tray 502 to mitigate or prevent deflection of the tray along the x, y, and / or z axes during installation, use in a corresponding vehicle, or removal of the battery tray 502. In some embodiments, the reinforcing ridge 524 of each of the first side 518a and the second side 518b may extend the entire length 518. In other embodiments, the reinforcing ridge 524 of one of the first side 518a and the second side 518b may extend only a portion of the length 518, while the reinforcing ridge of the other of the first side 518a and the second side 518b may extend the entire length 518. In yet another embodiment, the reinforcing ridge 524 of each of the first side 518a and the second side 518b may extend only a portion of the length 518. In some embodiments, only one of the first side 518a and the second side 518b may include the reinforcing ridge 524. The reinforcing ridge 524 can be U-shaped, L-shaped, or any other suitable shape to reduce or prevent the battery tray 502 from flexing. Each reinforcing ridge 524 may include a sliding surface 526 configured to cooperate with a support rail 310 on each of the side panels 302a, 302b to slide the battery tray 502 into the battery pack module 176. The sliding surface 526 can be a flat bottom surface, an L-shaped bracket, a U-shaped channel, or a sliding rail, such as a nylon sliding rail.

[0107] For further reference Figure 9 and Figure 10Battery module 176 may include cable 530 for electrically connecting battery packs 504 together and / or electrically connecting them to mining truck 100. Cable 530 may include main cable 532 and multiple layer cables 534—one layer cable 534 for each battery pack layer 500. In some embodiments, each battery pack 504 of a corresponding battery pack layer 500 may be electrically connected in parallel to the layer cable 534, such that one of the battery packs 504 can be removed without interrupting the current flow from the remaining battery packs. In other embodiments, each battery pack 504 of a corresponding battery pack layer 500 may be electrically connected in series to the layer cable 534.

[0108] Current flowing from the connected battery pack can be supplied to the corresponding layer cable 534 and via the layer cable 534 to the corresponding high-voltage interface box 536 at the second end 516 of the battery tray 502. The corresponding high-voltage interface box 536 can transmit current from the layer cable 534 to the main cable 532. Each corresponding layer cable 534 can extend over the entire length of the corresponding battery tray 502 of its corresponding battery pack layer 500. In other embodiments, each corresponding layer cable 534 can extend a portion of the length of the corresponding battery tray 502 of its corresponding battery pack layer 500, but defines a length that facilitates connection of each battery pack 504. The main cable 532 can extend vertically along at least a portion of the height of the battery pack module 176 to facilitate connection of each high-voltage interface box 536 as discussed further herein.

[0109] The main cable 532 can be connected to the main battery high-voltage junction box / low-voltage system 410 located on the upper mounting surface 312 (e.g., Figures 7A to 7B (As shown). In other words, current from battery pack 504 can flow through the corresponding layer cable 534, through the high-voltage interface box 536, into the main cable 532, and reach the main battery high-voltage connection box / low-voltage system 410 to power the mining truck. The main cable 532 can be connected in parallel or in series to each high-voltage interface box 536 of each battery pack layer 500. During the service of battery pack module 176, the operator can disconnect the layer cable 534 from its corresponding high-voltage interface box 536 to ensure that no current flows through the corresponding battery pack 504 of the corresponding battery tray 502.

[0110] Still referencing Figure 9 and Figure 10The battery pack module 176 may include a cooling system including cooling lines 600. Cooling lines 600 may include a main coolant supply line 602, a main coolant return line 604, and a battery pack layer coolant line 606 at each battery pack layer 500. The main coolant supply line 602 may be fluidly coupled to a coolant fluid source and supply coolant to components of the battery pack module 176 as further described herein.

[0111] For example, coolant can flow into the main supply line 602 and then into each battery layer 500 at the second end 516 of the battery tray 502 via the battery layer coolant line 606. Coolant can be supplied to each battery layer 500 through the corresponding battery layer coolant line 606. The battery layer coolant line 606 can branch from the main supply line 602, allowing the battery layer coolant lines 606 to be connected in parallel. In other embodiments, the battery layer coolant lines 606 can be fluidly connected in series to the main supply line 602. Each battery layer coolant line 606 can be substantially similar to each other.

[0112] The battery pack layer coolant line 606 can extend across the second side 518b of the corresponding battery tray 502. The battery pack layer coolant line 606 can be mounted on the layer coolant line bracket 607 of the corresponding battery tray 502. Figures 8A to 8C Support. In other embodiments, the battery pack layer coolant line 606 may extend through the first side 518a. In yet another embodiment, the layer coolant line mounting bracket 607 may be coupled to the first side plate 302a or the second side plate 302b at the level of the corresponding battery pack layer 500. Other mechanisms and methods for supporting the battery pack layer coolant line 606 for the purposes further described herein may be used to facilitate the coupling of the battery pack layer coolant line 606 to the necessary components of the battery pack module 176 for operation as further described herein.

[0113] The battery pack layer coolant lines 606 may include layer supply cooling lines 608 and layer return cooling lines 610. Each layer supply cooling line 608 branches via a plurality of layer supply branch cooling lines 612a to each corresponding battery pack 504 of the corresponding battery pack layer 500, such that each battery pack 504 is connected to the layer supply line 608, i.e., each battery pack 504 may be connected to its own corresponding layer supply branch cooling line 612a. In some embodiments, the layer supply cooling lines 608 may be connected in parallel to the battery pack 504 via the layer supply branch cooling lines 612a. In other embodiments, the layer supply cooling lines 608 may be connected in series to the battery pack 504 via the layer supply branch cooling lines 612a. Coolant may flow from a coolant fluid source into the main cooling line 602, each layer supply cooling line 608, and each layer supply branch cooling line 612a, reaching each battery pack 504.

[0114] Coolant cools the batteries and returns via layer return line 610. Layer return line 610 branches via a plurality of layer return branch cooling lines 612b to each corresponding battery pack 504 of the corresponding battery pack layer 500, such that each battery pack 504 is connected to layer return line 610, i.e., each battery pack 504 can be connected to its own corresponding layer return branch cooling line 612b. In some embodiments, layer return line 610 may be connected to battery pack 504 in parallel via layer return branch cooling lines 612b. In other embodiments, layer return line 610 may be connected to battery pack 504 in series via layer return branch cooling lines 612b. Each layer return line 610 can be fluidly connected to the main coolant return line 604 at its corresponding battery layer 500, allowing returned fluid to flow through the layer return line 610 and into the main coolant return line 604 for delivery to a heat exchanger or other cooling mechanism and to be recirculated back into the main coolant line 602, dumped, or otherwise removed from the battery module 176. In some embodiments, during cold operating conditions, the returned coolant can be used to heat other components of the mining truck.

[0115] As described above, the cooling lines 600 can be connected in parallel, series, or in combination. In embodiments including parallel connections, such embodiments can achieve a more uniform coolant distribution between the battery pack 504 and / or battery pack layers 500. This distribution can further experience reduced pressure loss compared to other conventional cooling systems. These features allow for a more compact battery pack module 176.

[0116] Now refer to Figures 11A to 11CThe battery module 176 may include a front panel 201 corresponding to the front or first side of the battery module 176; a rear panel 208 corresponding to the rear or second side of the battery module 176; a first sidewall panel 203 extending from the front panel 201 to the rear panel 208 and corresponding to the third side of the battery module 176; a second sidewall panel 206 extending from the front panel 201 to the rear panel 208 and corresponding to the fourth side of the battery module 176; and / or a fifth side, or a top panel 210. The battery module 176 may also include at least one service access defined by or within one or more panels, such as a door, entrance, baffle, etc., to allow access to the interior of the battery module 176 as described above. For example, the service access as described herein may be defined by a portion of a corresponding panel (i.e., a portion of the corresponding panel may be cut off and / or covered with a baffle, removable cover, etc.) and / or the entire corresponding panel may be used as a service access.

[0117] For example, the first service access 224 may be defined within or by the first sidewall panel 203 of the battery pack module 176, such that removing part or all of the first sidewall panel 203 or doors, baffles, etc. corresponding to the first sidewall panel 203 can be provided to the side panels 302a, 302b and the battery tray 502 via the first service access 224. Figures 8A to 8B ), Layer 534 ( Figures 8A to 10 ), and / or battery pack layer cooling pipe line 606 ( Figures 8A to 10 Access to ).

[0118] The second service access 220 may be defined within or by the second sidewall panel 206. For example, the second sidewall panel 206 may include a first portion 206a corresponding to the second service access 220, the first portion 206a being arranged such that a first edge of the first portion 206a is adjacent to an edge of the rear panel 208 and a second edge of the first portion 206a is adjacent to an edge of a second portion 206b of the second sidewall panel 206. The second portion 206b of the second sidewall panel 206 may correspond to the third service access 222 discussed further herein.

[0119] The second sidewall panel 206 can be attached to one of the side panels 302a and 302b, and is illustratively attached to the second side panel 302b. Removing part or all of the first portion 206a of the second sidewall panel 206, or removing the door, baffle, etc. corresponding to the first portion 206a of the second sidewall panel 206, can provide access to the battery wiring 530, main cable 532, layer cable 534, high-voltage interface box 536, cooling pipe line 600 and / or battery pack layer cooling pipe line 606 via the second service access 220.

[0120] As described above, the third service access 222 may be defined within or by the second portion 206b of the second sidewall panel 206. The second portion 206b of the second sidewall panel 206 may be arranged such that a first edge is adjacent to the edge of the front panel 201 and a second edge is adjacent to the second edge of the first portion 206a of the second sidewall panel 206, as discussed above. Removing part or all of the second portion 206b of the second sidewall panel 206 may provide access to the battery tray 502, the layer cable 534, and the battery pack layer cooling line 606 via the third service access 222.

[0121] The first service access 224 and the third service access 222 can be similar, as they each provide similar access to the interior of the battery pack module 176 and its components and / or contents. However, in some embodiments, the area of ​​the third service access 222 and / or the second portion 206b of the second sidewall panel 206 may be smaller than that of the first service access 224 and / or the first sidewall panel 203. In other embodiments, the area of ​​the third service access 222 and / or the second portion 206b of the second sidewall panel 206 may be the same as or larger than that of the first service access 224 and / or the first sidewall panel 203. For example, in some embodiments, the second sidewall panel 206 may include only one portion consistent with the second portion 206b and the third service access 222; that is, in some embodiments, the second sidewall panel 206 does not include the first portion 206a or the second service access 220. In such embodiments, components accessible via the second service access 220 may be accessible via the third service access 222.

[0122] The fourth service access 226 may be defined within or by the front panel 201 of the battery pack module 176. Removing part or all of the front panel 201 or the corresponding door, baffle, etc., may provide access to the end tray locking plate 404 and tray lifting feature 522 of each battery tray 502 via the fourth service access 226. The fifth maintenance access 228 may be defined within or by the top panel 210 to cover the connection box and the top reinforcing tray 306. Removing part or all of the top panel 210 or the corresponding door, baffle, etc., may provide access to the connection box and the top reinforcing tray 306 via the fifth maintenance access 228.

[0123] While service accesses 220, 222, 224, 226, and 228 are described herein as being associated with a particular panel and in a particular arrangement providing access to a particular component, it should be understood that such description is intended only as an example, and some embodiments may have alternative arrangements of accesses and panels within the spirit of this disclosure. For example, in some embodiments, each panel may include only one service access, while in other embodiments, each panel may include multiple service accesses. In other embodiments, one or more panels may not include service accesses.

[0124] In some embodiments, at least a portion of the first portion 206a of the second sidewall panel 206 may be removed from or otherwise moved away from the second side of the battery pack module 176 to expose cables 530 and cooling lines 600, including main cables 532, layer cables 534, high-voltage interface boxes 536, main coolant supply lines 602, main coolant return lines 604, and / or battery pack layer cooling lines 606. The corresponding layer cable 534 of a selected battery tray layer 500 may be disconnected from the corresponding high-voltage interface box 536 to interrupt current from all battery packs 504 corresponding to the battery pack layer 500 being maintained.

[0125] A portion or all of the front panel 201 may be removed from the front of the battery pack module 176, or otherwise moved away from the front of the battery pack module 176 to expose the end locking plate 404. The corresponding end locking plate 404 of the battery tray 502 of the selected battery pack layer 500 may be decoupled from the battery pack module 176 to expose the end plate 520 of the corresponding battery tray 502. Tools or other removal devices may be inserted into the tray lifting feature 522 of the corresponding battery tray 502 to slide the battery tray 502 at least partially out of the battery pack module 176 along the sliding surface of the corresponding support rail 310 of the corresponding battery pack layer 500. The individual battery packs 504 of the selected battery tray 502 may then be disconnected and / or otherwise maintained at the battery pack level.

[0126] Once service is complete, the battery tray 502 can slide back into the battery module 176 along the sliding surface of the corresponding support rail 310 of the corresponding battery layer 500. The layer cable 534 can then be reconnected to the corresponding high-voltage interface box 536. The corresponding end tray locking plate 404 can be reconnected to the battery module 176, and part or all of the front panel 201 and / or the first portion 206a of the second sidewall panel 206 can be returned to their proper positions and connected to the battery module 176 in the appropriate place.

[0127] In some embodiments, a portion or all of the first sidewall panel 203, a second portion 206b of the second sidewall panel 206, and / or the top panel 210 may be removed from the battery module 176, or otherwise removed from the corresponding portions of the battery module 176, to maintain components of the battery module 176, i.e., via the corresponding access as described above. For example, the main battery high-voltage junction box / low-voltage system 410 may be accessed by removing a portion or all of the top panel 210 and / or removing a portion or all of the top panel 210 from the top of the battery module 176.

[0128] While this disclosure has been described as having an exemplary design, it may be further modified within the spirit and scope of this disclosure. Therefore, this application is intended to cover any variations, uses, or modifications of the content of this disclosure using its general principles. Furthermore, this application is intended to cover such deviations from this disclosure within the scope of known or conventional practice in the field to which this disclosure pertains.

[0129] aspect

[0130] Aspect 1 is a layered battery pack module configured for installation on a mining truck, the layered battery pack module comprising: a support structure including a first support beam and a second support beam, each of the first and second support beams including a vertical portion and a horizontal portion, the distal end of the vertical portion being coupled to the distal end of the horizontal portion such that an angle is defined between the vertical and horizontal portions; a first side plate coupled to the vertical and horizontal portions of the first support beam; a second side plate coupled to the vertical and horizontal portions of the second support beam, the second side plate being positioned opposite the first side plate; and a plurality of battery pack layers defined between the first and second side plates.

[0131] Aspect 2 is a layered battery pack module of aspect 1, and further includes multiple battery pack trays, each of the multiple battery pack trays being removably coupled to a corresponding battery pack layer in the multiple battery pack layers.

[0132] Aspect 3 is a layered battery pack module of aspect 2, wherein each of the plurality of battery pack trays includes: a battery tray surface; and at least one battery pack coupled to the battery tray surface; wherein each of the plurality of battery pack trays is configured to slide onto a sliding surface of a corresponding battery pack layer in the plurality of battery pack layers.

[0133] Aspect 4 is a layered battery pack module of aspect 3, and further includes a first end plate connected to the far end of the battery tray surface and a second end plate connected to the near end of the battery tray surface, such that the first end plate and the second end plate extend in a direction perpendicular to the battery tray surface.

[0134] Aspect 5 is a layered battery pack module of any one of Aspects 3-4, wherein the sliding surface of each of the plurality of battery pack layers includes a first support rail connected to a first side plate and extending the length of the first side plate, and a second support rail connected to a second side plate and opposite to and parallel to the first support rail, the second support rail extending the length of the second side plate.

[0135] Aspect 6 is a layered battery pack module of any one of aspects 1-5, and also includes a top reinforcing tray attached to the upper part of each of the first side panel and the second side panel.

[0136] Aspect 7 is a layered battery pack module of any one of aspects 1-6, further comprising: a first mounting pin connected to a proximal end of a vertical portion of the first support beam; and a second mounting pin connected to a proximal end of a vertical portion of the second support beam.

[0137] Aspect 8 is a layered battery pack module of any of Aspects 1-7, and further includes a back plate extending between a first side plate and a second side plate, the back plate including mounting brackets configured to be coupled to a lower mounting component of a mining truck.

[0138] Aspect 9 is a layered battery pack module configured for installation on a mining truck, the layered battery pack module comprising: a first side plate corresponding to a first side of the layered battery pack module; a second side plate corresponding to a second side of the layered battery pack module; a plurality of battery pack layers between the first side plate and the second side plate, each of the plurality of battery pack layers defining a sliding surface; and a plurality of battery pack trays, each of the plurality of battery pack trays being configured to be removably received by a corresponding battery pack layer of the plurality of battery pack layers; wherein each of the plurality of battery pack trays includes: a battery tray surface; and at least one battery pack coupled to the battery tray surface.

[0139] Aspect 10 is a layered battery pack module of aspect 9, and further includes a first end plate connected to the distal end of the battery tray surface and a second end plate connected to the proximal end of the battery tray surface, such that the first end plate and the second end plate extend in a direction perpendicular to the battery tray surface.

[0140] Aspect 11 is a layered battery pack module of aspect 10, wherein each of the first end plate and the second end plate includes a tray lifting feature.

[0141] Aspect 12 is a layered battery pack module of any one of aspects 10-11, wherein the sliding surface of each of the plurality of battery pack layers is defined by: a first support rail connected to the first side plate and extending the length of the first side plate; and a second support rail connected to the second side plate and extending the length of the second side plate.

[0142] Aspect 13 is a layered battery pack module of aspect 12, wherein each of the plurality of battery pack trays includes a first slide rail configured to be slidably connected to the first support rail and a second slide rail configured to be slidably connected to the second support rail.

[0143] Aspect 14 is a layered battery pack module of any of Aspects 9-13, wherein each of the plurality of battery pack trays is configured to slide along a sliding surface of the corresponding battery pack layer in a direction away from the chassis of the mining truck.

[0144] Aspect 15 is a layered battery pack module of any of Aspects 9-14, and also includes a locking mechanism to hold each of the plurality of battery pack trays in position relative to the corresponding battery pack layer.

[0145] Aspect 16 is a layered battery pack module configured for mounting on a mining truck, the layered battery pack module comprising: a first support beam having a first end and a second end; a first plate coupled to the first support beam to form a first sidewall; a second plate coupled to the first support beam to form a rear panel, the second plate including a mounting bracket positioned closer to the second end of the first support beam than the first end of the first support beam, and the mounting bracket being configured to be coupled to a lower mounting member of the vehicle chassis; and a first pivot pin coupled to the first end of the first support beam but not the second end of the first support beam, and extending from the first end of the first support beam, the first pivot pin being configured to be received by a pin receiving mounting member of the vehicle chassis.

[0146] Aspect 17 is a layered battery pack module of aspect 16, further comprising: a second support beam having a first end and a second end, the second support beam being connected to the second plate opposite to the first support beam; a third plate being connected to the second support beam to form a second sidewall; and a second pivot pin being connected to one of the first end of the second support beam and the third plate and extending from one of the first end of the second support beam and the third plate, the third plate being closer to the first end of the second support beam than the second end of the second support beam, the second pivot pin being configured to be received by the pin receiving mount of the chassis of the vehicle.

[0147] Aspect 18 is a layered battery module of any of Aspects 16-17, wherein the first pivot pin extends in a generally perpendicular direction relative to the first support beam or the first plate.

[0148] Aspect 19 is a layered battery pack module of any of Aspects 16-18, wherein the mounting bracket is configured to be removably attached to a lower mounting component of the vehicle chassis.

[0149] Aspect 20 is a layered battery pack module of any of Aspects 16-19, wherein the lower mounting to the vehicle chassis includes vibration mitigation elements.

[0150] Aspect 21 is a layered battery pack module of any one of aspects 1-8, wherein the plurality of battery pack layers includes seven battery pack layers.

[0151] Aspect 22 is a layered battery pack module of aspect 3, wherein each of the multiple battery pack trays includes three battery packs.

[0152] Aspect 23 is a layered battery pack module of aspect 5, wherein each of the plurality of battery pack trays is configured to slide onto a first support rail and a second support rail of the corresponding battery pack layer in the plurality of battery pack layers.

[0153] Aspect 24 is a layered battery pack module of any of Aspects 1-8, wherein each of the first side panel and the second side panel includes a bottom mounting surface on the bottom of the first side panel and the second side panel and an upper mounting surface on the upper part of the first side panel and the second side panel.

[0154] Aspect 25 is a layered battery module of aspect 24, wherein at least one of the mudguard, waterproofing plate and fluid seal is removably coupled to at least one of the bottom mounting surface and the upper mounting surface.

[0155] Aspect 26 is a layered battery pack module of any of Aspects 24-25, and further includes a top mounting surface connected to the top of each of the first side panel, the second side panel and the back panel extending between the first side panel and the second side panel, the top being located above the upper portion of the first side panel and the second side panel and the upper portion of the back panel.

[0156] Aspect 27 is a layered battery pack module of aspect 26, and further includes: a first service access panel connected to the first side panel; a second service access panel and a third service access panel connected to the second side panel; a fourth service access panel connected to the front panel of the battery pack module; and a fifth service access panel connected to the top panel of the battery pack module, the top panel being connected to the top mounting surface.

[0157] Aspect 28 is a layered battery pack module of any one of aspects 1-8, wherein the layered battery pack module has a single-unit design.

[0158] Aspect 29 is a layered battery pack module of any of Aspects 9-15, wherein each of the plurality of battery pack trays is configured to slide into one of the plurality of battery pack layers.

[0159] Aspect 30 is a layered battery pack module of any one of Aspects 9-15, wherein the plurality of battery pack layers includes seven battery pack layers.

[0160] Aspect 31 is a layered battery pack module of any one of aspects 9-15, wherein the plurality of battery packs includes three battery packs.

[0161] Aspect 32 is a layered battery pack module of any of Aspects 9-15, wherein a first end plate and a second end plate are connected to the surface of the battery tray such that the mounting lips of the first end plate and the second end plate extend a certain distance parallel to the surface of the battery tray.

[0162] Aspect 33 is a layered battery pack module of any of Aspects 9-15, wherein each of a plurality of battery pack trays includes two reinforcing ridges, each of the two reinforcing ridges extending the length of the battery pack tray between the distal and proximal ends, wherein the two reinforcing ridges are configured to reduce bending of the battery pack.

[0163] Aspect 34 is a layered battery pack module of any of Aspects 9-15, wherein the surface of the battery tray includes at least one opening configured to allow fluid to drain through the battery pack tray.

[0164] Aspect 35 is a layered battery pack module of any one of aspects 9-15, and further includes a support structure comprising a first support beam and a second support beam, each of the first support beam and the second support beam comprising a vertical portion and a horizontal portion, wherein the distal end of the vertical portion is connected to the distal end of the horizontal portion to form an angle therebetween.

[0165] Aspect 36 is a layered battery pack module of aspect 35, and further includes: a first mounting pin connected to the proximal end of the vertical portion of the first support beam; and a second mounting pin connected to the proximal end of the vertical portion of the second support beam.

[0166] Aspect 37 is a layered battery pack module of any one of aspects 9-15, further comprising: a rear panel having a mounting bracket; a first mounting pin connected to a first side of the layered battery pack module; and a second mounting pin connected to a second side of the layered battery pack module.

[0167] Aspect 38 is a layered battery pack module of aspect 37, wherein the mounting bracket is configured to be attached to the lower mounting of the mining truck.

[0168] Aspect 39 is a layered battery pack module of any of Aspects 36-38, wherein the battery pack module is configured to be mounted to a mining truck via mounting pins.

[0169] Aspect 40 is a layered battery pack module of any one of Aspects 9-15, further comprising cooling pipelines including: a main cooling supply pipeline fluidly connected to a coolant fluid source; a main return cooling pipeline; and a plurality of battery pack layer cooling pipelines fluidly connected in parallel to the main supply cooling pipeline and the main return cooling pipeline, each of the plurality of battery pack layer cooling pipelines corresponding to one of the plurality of battery pack layers.

[0170] Aspect 41 is a layered battery pack module of aspect 40, wherein each of the plurality of battery pack layer cooling pipelines includes: a layer supply pipeline fluidly connected in parallel to a plurality of layer supply branch pipelines, each of the plurality of layer supply branch pipelines corresponding to one of the plurality of battery packs; and a layer return pipeline fluidly connected in parallel to a plurality of layer return branch pipelines, each of the plurality of layer return branch pipelines corresponding to one of the plurality of battery packs.

[0171] Aspect 42 is a layered battery pack module of aspect 40, wherein each of the plurality of battery pack layer cooling pipelines includes: a layer supply pipeline fluidly connected in series with a plurality of layer supply branch pipelines, each of the plurality of layer supply branch pipelines corresponding to one of the plurality of battery packs; and a layer return pipeline fluidly connected in series with a plurality of layer return branch pipelines, each of the plurality of layer return branch pipelines corresponding to one of the plurality of battery packs.

[0172] Aspect 43 is a layered battery pack module of any of Aspects 9-15, and further includes a battery cable comprising: a main cable; and a plurality of layer cables electrically connected in parallel to the main cable, each of the plurality of layer cables corresponding to one of the plurality of battery pack layers.

[0173] Aspect 44 is a layered battery pack module of aspect 43, wherein each of the plurality of layer cables corresponds to one of the plurality of battery pack layers and is electrically connected to one of the plurality of battery packs, such that the plurality of battery packs within a common battery pack layer of the plurality of battery pack layers are connected in parallel.

[0174] Aspect 45 is a layered battery pack module of any one of Aspects 9-15, wherein the layered battery pack module has a single-unit design.

[0175] Aspect 46 is a vehicle having a layered battery pack module, the vehicle comprising: a first wheel coupled to a first side of a chassis in a first forward position; a second wheel coupled to the first side of the chassis in a first rearward position; a support structure for the battery pack module coupled to the first side of the chassis in a position between the first wheel and the second wheel, the battery pack module comprising a plurality of battery pack layers arranged vertically, each of the plurality of battery pack layers comprising at least one battery pack, wherein each of the plurality of battery pack layers comprises a tray operation line, each tray operation line being coupled to each battery pack in the at least one battery pack of the corresponding battery pack layer, and each tray operation line extending to a first end of the battery pack module; and a vertical operation cable extending vertically along at least a portion of the first end of the battery pack module to a first access point; wherein the first access point is located within an access area defined after the first wheel.

[0176] Aspect 47 is the vehicle of aspect 46, wherein each battery pack layer includes multiple battery packs, and each tray operation line connects each of the multiple battery packs in the corresponding battery pack layer in series.

[0177] Aspect 48 is the vehicle of aspect 46, wherein each battery pack layer includes multiple battery packs, and each tray operation line connects each of the multiple battery packs in the corresponding battery pack layer in parallel.

[0178] Aspect 49 is a vehicle of any of Aspects 46-48, wherein each pallet operating line and the vertical operating cable are electronic cables.

[0179] Aspect 50 is the vehicle of aspect 49, wherein each pallet operating line is connected to the vertical operating cable via a high-voltage electrical interface box.

[0180] Aspect 51 is a vehicle of any of Aspects 56-50, wherein the first access point is a high-voltage electrical box.

[0181] Aspect 52 is a vehicle of any one of aspects 46-51, wherein the first access point is located on the upper mounting surface of the battery pack module.

[0182] Aspect 53 is a vehicle of any of Aspects 46-49, wherein each pallet operating line and vertical operating cable is a cooling line.

[0183] Aspect 54 is a vehicle of any of Aspects 46-53, wherein the access point can be accessed from the access area via a removable service panel of the battery pack module.

[0184] Aspect 55 is a battery pack module for a vehicle, the battery pack module comprising: a front panel; a rear panel positioned opposite the front panel; a first side panel extending between the front panel and the rear panel, the first side panel having a first service access; and a plurality of battery pack layers vertically arranged within the front panel, the rear panel and the first side panel, each of the plurality of battery pack layers comprising a battery pack, wherein each of the plurality of battery pack layers includes a tray operation line removably coupled to the battery pack and accessible via the first service access to disconnect the tray operation line from the battery pack.

[0185] Aspect 56 is the battery module of aspect 55, where the service access is one of the doors, entrances or baffles.

[0186] Aspect 57 is a battery module of aspect 55 or aspect 56, and further includes: a second side panel extending between the front panel and the rear panel opposite to the first side panel; a top panel extending between the front panel, the rear panel, the first side panel and the second side panel; and a second inlet corresponding to one of the front panel, the rear panel, the second side panel and the top panel.

[0187] Aspect 58 is a battery pack module of any of aspects 55-57, wherein the tray operation line extends to the first end of the battery pack module.

[0188] Aspect 59 is the battery pack module of aspect 58, and also includes a vertical operating cable that extends vertically along at least a portion of the first end of the battery pack module to a third access point.

[0189] Aspect 60 is a battery pack module of any of Aspects 55-59, wherein each battery pack layer includes a plurality of battery packs, and the tray operation line is connected in series to each of the plurality of battery packs in the corresponding battery pack layer.

[0190] Aspect 61 is a battery pack module of any of Aspects 55-59, wherein each battery pack layer includes multiple battery packs, and tray operation lines are connected in parallel to each of the multiple battery packs in the corresponding battery pack layer.

[0191] Aspect 62 is a battery pack module of any one of aspects 55-61, wherein the tray operation line is an electronic cable.

[0192] Aspect 63 is a battery pack module of any one of Aspects 55-61, wherein the tray operation line includes: a layer supply branch cooling line fluidly connected to a layer supply cooling line corresponding to a battery pack layer among the plurality of battery pack layers; and a layer return branch cooling line fluidly connected to a layer return cooling line corresponding to a battery pack layer among the plurality of battery pack layers.

[0193] Aspect 64 is the battery pack of aspect 63, wherein the battery pack layer includes multiple battery packs, multiple layer supply branch cooling lines, and multiple layer return branch cooling lines, such that: each of the multiple layer supply branch cooling lines corresponds to one battery pack of the multiple battery packs; each of the multiple layer return branch cooling lines corresponds to one battery pack of the multiple battery packs; the layer supply cooling lines are fluidly connected to each of the multiple layer supply branch cooling lines; and the layer return cooling lines are fluidly connected to each of the multiple layer return branch cooling lines.

[0194] Aspect 65 is a battery pack module of aspect 63 or aspect 64, and further includes: a main cooling supply line fluidly connected to a coolant fluid source and the layer supply cooling line; and a main cooling return line fluidly connected to the layer supply cooling line.

[0195] Aspect 66 is a battery pack tray for a layered battery pack module, the battery pack tray comprising: a tray including a tray surface, a distal end, a proximal end, a first side, and a second side, the tray being configured to support at least one battery pack on the tray surface, the first side including a first sliding surface and the second side including a second sliding surface; a first end plate coupled to the distal end of the tray and extending in a direction perpendicular to the tray surface; and a second end plate coupled to the proximal end of the tray; wherein the first end plate and the second end plate each include a reinforcing lip extending parallel to the tray surface from the first end plate and the second end plate.

[0196] Aspect 67 is the battery pack tray of aspect 66, wherein the battery pack tray is configured to slide onto a layered battery pack module on a first sliding surface and a second sliding surface.

[0197] Aspect 68 is the battery pack tray of aspect 66 or aspect 67, wherein a first sliding surface is defined by a first sliding rail and a second sliding surface is defined by a second sliding rail.

[0198] Aspect 69 is a battery pack tray of any of aspects 66-68, wherein each of the first end plate and the second end plate includes a tray lifting opening.

[0199] Aspect 70 is a battery pack tray of any of aspects 66-69, further comprising a first reinforcing ridge and a second reinforcing ridge, the first reinforcing ridge extending the length of a first side of the tray between a distal end and a proximal end of the tray, and the second reinforcing ridge extending the length of a second side of the tray between a distal end and a proximal end of the tray.

[0200] Aspect 71 is a battery pack tray of any of aspects 66-70, wherein the tray surface includes a first tray support beam extending between a distal end of the tray and a proximal end of the tray, and a second tray support beam extending between a first side of the tray and a second side of the tray.

[0201] Aspect 72 is the battery pack tray of aspect 71, wherein a first tray support beam and a second tray support beam define a plurality of tray surface openings configured to allow fluid to drain through the slidable battery pack tray.

[0202] Aspect 73 is the battery pack tray of aspect 71 or aspect 72, wherein a first tray support beam and a second tray support beam are included in a plurality of tray support beams, the plurality of tray support beams forming a grid structure on the tray surface.

[0203] Aspect 74 is a battery pack tray of any of aspects 66-73, and further includes a cooling line mounting bracket configured to support parallel cooling lines connected to at least one battery pack on the surface of the tray.

[0204] Aspect 75 is a battery pack tray of any of aspects 66-74, and further includes a high-voltage interface box configured to be connected to a parallel cable connected to at least one battery pack on the surface of the tray.

[0205] Aspect 76 is a battery pack module for a mining truck, the layered battery pack module comprising: a plurality of battery pack trays, each of the plurality of battery pack trays being removably coupled to a corresponding battery pack layer in a plurality of battery pack layers, each of the plurality of battery pack trays including at least one battery pack; a coolant piping system configured to cool the at least one battery pack, the coolant piping system including: a main supply cooling line fluidly coupled to a coolant fluid source; a main return cooling line; and a plurality of battery pack layer cooling lines fluidly coupled to the main supply cooling line and the main return cooling line, each of the plurality of battery pack layer cooling lines corresponding to one of the plurality of battery pack layers; and a battery wiring system configured to transmit current from the at least one battery pack in each of the plurality of battery pack layers to the mining truck, the battery wiring system including: a main cable; and a plurality of layer cables electrically coupled to the main cable, each of the plurality of layer cables corresponding to one of the plurality of battery pack layers.

[0206] Aspect 77 is a layered battery pack module of aspect 76, wherein each of the plurality of battery pack layer cooling lines is fluidly connected in parallel to the main supply cooling line and the main return cooling line.

[0207] Aspect 78 is a layered battery pack module of aspect 76, wherein each of the plurality of battery pack layer cooling lines is fluidly connected in series with the main supply cooling line and the main return cooling line.

[0208] Aspect 79 is a layered battery module of any of aspects 76-78, wherein each of the plurality of layered cables is electrically connected in parallel to the main cable.

[0209] Aspect 80 is a layered battery module of any of aspects 76-78, wherein each of the plurality of layered cables is electrically connected in series to the main cable.

[0210] Aspect 81 is a layered battery pack module of any one of aspects 76-80, wherein each of the plurality of battery pack trays comprises: a battery tray surface defined by: a first side; a second side parallel to the first side; a distal end connecting the first side to the second side; and a proximal end connecting the first side to the second side, the proximal end being spaced apart from the distal end by the first side and the second side; and a plurality of battery support beams extending from at least one of: the first side to the second side; and the distal end to the proximal end.

[0211] Aspect 82 is a layered battery pack module of aspect 81, wherein the at least one battery pack is connected to at least one of the plurality of battery support beams.

[0212] Aspect 83 is a layered battery pack module of any of Aspects 76-82, wherein each battery pack layer comprises a plurality of battery packs and each of the plurality of battery pack layer cooling lines comprises: a layer supply line fluidly connected in parallel to a plurality of layer supply branch lines, each of the plurality of layer supply branch lines corresponding to one of the plurality of battery packs; and a layer return line fluidly connected in parallel to a plurality of layer return branch lines, each of the plurality of layer return branch lines corresponding to one of the plurality of battery packs.

[0213] Aspect 84 is a layered battery pack module of any of Aspects 76-82, wherein each battery pack layer includes a plurality of battery packs and each of the plurality of battery pack layer cooling lines includes: a layer supply line fluidly connected in series with a plurality of layer supply branch lines, each of the plurality of layer supply branch lines corresponding to one of the plurality of battery packs; and a layer return line fluidly connected in series with a plurality of layer return branch lines, each of the plurality of layer return branch lines corresponding to one of the plurality of battery packs.

[0214] Aspect 85 is a layered battery pack module of any of Aspects 76-84, wherein each battery pack layer includes multiple battery packs, and each of the multiple layer cables is electrically connected in parallel to the multiple battery packs.

[0215] Aspect 86 is a layered battery pack module of any of aspects 76-84, wherein each battery pack layer includes multiple battery packs, and each of the multiple layer cables is electrically connected in series to the multiple battery packs.

[0216] Aspect 87 is a method for servicing a layered battery pack module on a mining truck, the method comprising: removing a first service access panel from a first side of the layered battery pack module; disconnecting battery wiring from the high-voltage electrical interface box of the first battery pack layer, thereby interrupting current flow from any of a plurality of battery packs on the battery pack tray of the first battery pack layer; removing a terminal service access panel from the front side of the layered battery pack module; and sliding the battery pack tray out of the layered battery pack module.

[0217] Aspect 88 is the method of aspect 87, and also includes disconnecting the tray locking plate from the battery pack tray end plate.

[0218] Aspect 89 is a method of aspect 87 or aspect 88, further comprising at least one of the following: sliding the battery pack tray into the battery pack module; connecting a tray locking plate to a battery pack tray end plate; connecting the end service access panel to the front side of the layered battery pack module; electrically connecting the battery cable to the high-voltage interface box of the first battery pack layer; and connecting the first service access panel to the first side of the layered battery pack module.

[0219] Aspect 90 is a method of any one of aspects 87-89, further comprising removing a second service access panel from at least one of the second side or top side of the layered battery pack module.

[0220] Aspect 91 is a method of any one of aspects 87-90, wherein sliding the battery pack tray out of the layered battery pack module comprises: inserting a tool into a lifting feature on the distal end of the battery pack tray; and using the tool to slide the battery pack tray out of the battery pack module.

Claims

1. A vehicle having a layered battery pack module, the vehicle comprising: The first wheel is connected to the first side of the chassis in the first forward position; The second wheel is connected to the first side of the chassis at the first rearward position; A support structure for a battery pack module, wherein the battery pack module is connected to the first side of the chassis at a position between the first wheel and the second wheel, the battery pack module includes a plurality of battery pack layers arranged vertically, each of the plurality of battery pack layers includes at least one battery pack, wherein each of the plurality of battery pack layers includes a tray operation line, each tray operation line is connected to each battery pack in the at least one battery pack of the corresponding battery pack layer, and each tray operation line extends to a first end of the battery pack module; as well as A vertical operating cable extends vertically along at least a portion of the first end of the battery pack module to the first access point; The first access point is located within the access area limited to the first round.

2. The vehicle of claim 1, wherein each battery pack layer comprises a plurality of battery packs, and each tray operation line connects each of the plurality of battery packs in the corresponding battery pack layer in series.

3. The vehicle of claim 1, wherein each battery pack layer comprises a plurality of battery packs, and each tray operation line connects each of the plurality of battery packs in the corresponding battery pack layer in parallel.

4. The vehicle according to any one of claims 1 to 3, wherein each pallet operating line and the vertical operating cable are electronic cables.

5. The vehicle of claim 4, wherein each pallet operating line is connected to the vertical operating cable via a high-voltage interface box.

6. The vehicle according to any one of claims 1 to 3, wherein the first access point is a high-voltage electrical box.

7. The vehicle according to any one of claims 1 to 3, wherein the first access point is located on the upper mounting surface of the battery pack module.

8. The vehicle according to any one of claims 1 to 3, wherein each pallet operating line and the vertical operating cable are cooling lines.

9. The vehicle according to any one of claims 1 to 3, wherein the access point is accessible from the access area via a removable service panel of the battery pack module.

10. A battery pack module for a vehicle, the battery pack module comprising: Front panel; A rear panel, which is disposed opposite to the front panel; A first side panel extends between the front panel and the rear panel, and the first side panel has a first service access. as well as Multiple battery pack layers are vertically arranged within the front panel, the rear panel, and the first side panel. Each of the multiple battery pack layers includes a battery pack. Each of the multiple battery pack layers includes a tray operation line that is removably coupled to the battery pack and accessible via the first service access to disconnect the tray operation line from the battery pack.

11. The battery pack module of claim 10, wherein the service access is one of a door, an entrance, or a baffle.

12. The battery pack module according to claim 10, further comprising: A second side panel extends between the front panel and the rear panel, opposite to the first side panel; A top panel that extends between the front panel, the rear panel, the first side panel, and the second side panel; as well as The second access point corresponds to one of the front panel, the rear panel, the second side panel, and the top panel.

13. The battery pack module of claim 10, wherein the tray operation line extends to a first end of the battery pack module.

14. The battery pack module of claim 13, further comprising a vertical operating cable extending vertically along at least a portion of the first end of the battery pack module to a third access point.

15. The battery pack module of claim 10, wherein each battery pack layer comprises a plurality of battery packs, and the tray operation line is connected in series to each of the plurality of battery packs in the corresponding battery pack layer.

16. The battery pack module of claim 10, wherein each battery pack layer comprises a plurality of battery packs, and the tray operation line connects each of the plurality of battery packs in the corresponding battery pack layer in parallel.

17. The battery pack module of claim 10, wherein the tray operation line is an electronic cable.

18. The battery pack module according to any one of claims 10 to 17, wherein the tray operation line comprises: A layer supply branch cooling line is fluidly connected to a layer supply cooling line, the layer supply cooling line corresponding to a battery pack layer among the plurality of battery pack layers; as well as A layer return branch cooling line is fluidly connected to a layer return cooling line corresponding to one of the plurality of battery pack layers.

19. The battery pack module of claim 18, wherein the battery pack layer comprises a plurality of battery packs, a plurality of layer supply branch cooling lines, and a plurality of layer return branch cooling lines, such that: Each of the plurality of layer supply branch cooling pipelines corresponds to one of the plurality of battery packs; Each of the multiple layer return branch cooling pipelines corresponds to one of the multiple battery packs; The layer supply cooling line is fluidly connected to each of the plurality of layer supply branch cooling lines; as well as The layer return cooling line is fluidly connected to each of the plurality of layer return branch cooling lines.

20. The battery pack module according to claim 18, further comprising: A main cooling supply line, which is fluidly connected to a coolant fluid source and the stratified cooling supply line; as well as A main cooling return line is fluidly connected to the layer supply cooling line.

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