Electrical package

Abstract

An electrical pack comprising at least one battery, at least one electric motor, a battery charger for charging the at least one battery, a power converter, a cooling system, and a control system comprising at least one processor and a non-transitory computer readable medium.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 547,334, filed November 3, 2023, entitled "Electrical Package," the entire disclosure of which is incorporated herein by reference. Background Technology

[0003] Electricity can be used to power a wide variety of objects. The amount of electricity required to power an object may vary depending on the type of object. For example, a laptop may require less electricity to power than an oven. Summary of the Invention

[0004] In a first embodiment, an electrical package (electrical enclosure) includes at least one battery, at least one electric motor, a battery charger for charging the at least one battery, a power converter, a cooling system, and a control system including at least one processor and a non-transitory computer-readable medium.

[0005] In a second embodiment, a method includes: determining, by at least one processor, whether to activate a power converter of an electrical pack, wherein the electrical pack includes at least one battery, at least one electric motor, a battery charger for charging the at least one battery, the power converter, a cooling system, and a control system including the at least one processor and a non-transitory computer-readable medium, wherein instructions are stored on the non-transitory computer-readable medium; and determining, by the at least one processor, whether to activate the cooling system of the electrical pack. Attached Figure Description

[0006] Exemplary embodiments are described herein with reference to the accompanying drawings.

[0007] Figure 1 An electrical package according to an exemplary embodiment is depicted.

[0008] Figure 2 An electrical package and an exposed electrical package are depicted according to an exemplary embodiment.

[0009] Figure 3A Data related to the electrical package is depicted according to an exemplary embodiment.

[0010] Figure 3B Other data related to the electrical package are described according to exemplary embodiments.

[0011] Figure 4 An enclosure for an electrical package is depicted according to an exemplary embodiment.

[0012] Figures 5A-5D A perspective view of the back end of an electrical package according to an exemplary embodiment is depicted.

[0013] Figure 6A An exploded perspective view of the mechanical output of an electrical package according to an exemplary embodiment is depicted.

[0014] Figures 6B-6D A perspective view of a mechanical output assembly according to an exemplary embodiment is depicted.

[0015] Figure 7 A modular design of an electrical package according to an exemplary embodiment is depicted.

[0016] Figure 8 The components of an electrical package according to an exemplary embodiment are depicted.

[0017] Figure 9 An electrical package according to an exemplary embodiment is depicted.

[0018] Figure 10A An electrical package according to an exemplary embodiment is depicted.

[0019] Figure 10B Depicting according to exemplary embodiments Figure 10A The outer casing of the China Electric Packaging.

[0020] Figure 11A An exposed electrical package is depicted according to an exemplary embodiment.

[0021] Figure 11B Depicting according to exemplary embodiments Figure 11A Exploded view of the exposed electrical package.

[0022] Figure 12 The components of an electrical package according to an exemplary embodiment are depicted.

[0023] Figure 13 A perspective view of another rear end of an electrical package according to an exemplary embodiment is depicted. Detailed Implementation

[0024] Figure 1 An electrical package (electrical enclosure) 100 according to exemplary embodiments is depicted. In some examples described herein, the electrical package 100 can be used in a variety of applications. Specifically, the electrical package 100 can be used to provide power to a water pump 102, a vacuum cleaner and broom 104, a water sprayer 106, a cable puller 108, a wood chipper 110, and an air compressor 112. The electrical package 100 may be referred to as a general-purpose electrical package. Furthermore, the electrical package 100 can also be used to provide power to other external devices, such as a stump grinder.

[0025] The electrical package 100 can be used in applications with high power consumption, and the electrical package 100 may include one or more components that facilitate such applications, as described below.

[0026] Figure 2 An electrical package 200 and an exposed electrical package 202 are depicted according to an exemplary embodiment. Specifically, the electrical package 200 may be an industrial-grade electrical unit.

[0027] Electrical package 200 can be used as a housing for one or more components, as shown in exposed electrical package 202. In some examples, the components in electrical package 200 and exposed electrical package 202 may depend on the application of the electrical package.

[0028] According to an exemplary embodiment, Figure 3A Data related to the electrical pack is depicted. As shown in the figure, the data related to the electrical pack includes Table 300 and Figure 302. The electrical pack may include a battery with an energy rating of 30 kWh (312) and a battery type of LTC (314). The maximum continuous charge / discharge rate (316) may be 1C, and the maximum pulse charge / discharge rate (318) may be twice the maximum continuous charge / discharge rate (e.g., 2C). Additionally, the electrical pack may include a cooler (320), which may be a liquid cooler. Having a liquid cooler can help cool the battery more effectively and efficiently compared to having a non-liquid cooler (e.g., a fan), which may be particularly advantageous in high-energy applications. In some examples, the electrical pack may also include a battery charger that provides power (322) of 85-264 VAC. The auxiliary power (324) may be 12 VDC, and the pack weight (326) may be 1200 lbs. Furthermore, as shown in Figure 302, the electrical pack may include an electric motor with a power rating / peak power (304) of 30 / 60 kW. The electric motor may have a rated torque / peak torque of 100 / 200 Nm (306) and a rated speed of 3000 rpm (308). As shown in Table 302, the torque of the electric motor may decrease with increasing speed, while the power may increase with increasing speed. Furthermore, in some embodiments, the electric motor may also include a motor cooling type 310, which may be a liquid cooler.

[0029] Figure 3BData related to the electrical pack is depicted according to an exemplary embodiment. As shown, the data related to the electrical pack includes Table 350. As shown in Table 350, the electrical pack may include a battery with an energy 362 between 10 kWh and 400 kWh, and a battery chemistry type 364 of LFP, and a battery type of LTC and / or blade battery. The maximum continuous charge / discharge rate 366 may be 1C, and the maximum pulse charge / discharge rate 368 may be twice the maximum continuous charge / discharge rate (e.g., 2C). In some embodiments, the electrical pack may include a battery cooler having a battery cooling type 370, which may be a liquid cooler. Having a liquid cooler can help cool the battery more effectively and efficiently compared to having a non-liquid cooler (e.g., a fan), which may be particularly advantageous in high-energy applications. In other embodiments, the electrical pack may include a non-liquid air cooler. Furthermore, in some embodiments, the electric motor may also include an electric motor cooling type 360, which may include a liquid cooler and / or a non-liquid cooler. In some examples, the electrical pack may also include a battery charger connection 372, which may be an EV charger J1772 or a fast-charging CCS. The auxiliary power supply 374 may be 12-24 VDC, and the pack weight 376 may be 200-5000 lbs. Furthermore, as shown in Table 350, the electrical pack may include an electric motor with a power rating / peak power 354 of 10-250 kW. This electric motor may have a torque rating / peak torque 356 of 30-1200 Nm, and a rated speed 358 of 1400-6000 rpm.

[0030] In addition, the electrical pack may include an inverter, which can be integrated into the electric motor. The electrical pack may also include a color thin-film transistor liquid crystal (TFT LCD) display and a J1939 interface. In some examples, components of the electrical pack can be selected for high-energy-consumption applications. Specifically, components of the electrical pack can be selected to withstand operating temperatures from -30 to 140 degrees Fahrenheit. The electrical pack may have EV charging rates from 3.3 kW to 14 kW, and charging rates up to 100 kW for DC fast charging. Additionally and / or alternatively, the electrical pack may also include a remote monitoring system. Compared to other motor-driven devices, the electrical pack may have lower or zero emissions, lower maintenance costs, and less noise.

[0031] Figure 4A housing 400 for an electrical package is depicted according to an exemplary embodiment. The housing 400 may be designed with a battery structure and a motor mounting base. Furthermore, the base of the housing 400 may include a forklift slot. The forklift slot is configured to receive a portion of a forklift for lifting and transporting the housing 400. Additionally, the housing 400 may have air inlets and exhaust vents, and may also be configured to connect internal components to an EV charging station using a J1772. Furthermore, the housing 400 may include a control display for controlling the motor and displaying electrical parameters from the electrical equipment. Furthermore, the housing 400 may be designed with isolation devices to reduce vibration / shock to the electrical equipment. Additionally, the housing 400 may include a service door for servicing the electrical equipment.

[0032] In some embodiments, housing 400 includes an internal support for the electrical pack and an external panel. The external panel can then be seamlessly integrated with mounting brackets for each of the various components of the electrical pack, such as the battery, heat sink, motor, PDU, and charger. Additionally, in some embodiments, housing 400 may include a slide or base for the electrical pack.

[0033] 400mm enclosure can be sealed Figure 2 The exposed electrical package 202, and may include Figure 4 One or more components, such as the controller display and the J1772 power socket, are not shown. In some embodiments, in addition to the J1772 connector for EV charging, the electrical package may also include a CCS connection for DC charging.

[0034] Figure 5A A rear end 500 mounted to an electrical package according to an exemplary embodiment is depicted. In some embodiments, the rear end may have a housing 502 configured to connect to a motor 504 of the electrical package and an output end including an output shaft mount 506 and an output shaft 508. The housing may include a pulley 510 comprising a belt and a plurality of pulleys, including a tension pulley. The housing may also include a mounting pad and a bracket 512 configured to mount the housing onto a frame of the electrical package.

[0035] Figure 5B A rear end 500 is depicted connecting the motor 504 and the output shaft 508. In some examples, the output shaft 508 is configured to connect to an external device, such as a water pump, vacuum cleaner, water sprayer, air compressor, wood chipper, or cable tractor. The housing may also include a removable housing cover 514 configured to cover the pulleys and connect to the output shaft mounting base 506. In some examples, the motor 504 is configured to connect to the output end via a hand-operated key.

[0036] Figure 5C and 5DMultiple cutouts are depicted in the housing of the rear end 500 according to an exemplary embodiment. One cutout 516 is positioned to allow access to the belt of the pulley. Another cutout 518 is positioned to allow access to one of the pulleys. Another cutout 520 is positioned to allow access to the tensioner pulley of the pulley. In some examples, the rear end may include a removable cutout cover for covering the cutouts during operation of the electrical package.

[0037] Figure 6A An exploded view of a mechanical output 600 according to an exemplary embodiment is depicted. In some examples, the mechanical output 600 includes an electric motor 602, a hydraulic pump 604, a rear end 606, a pulley 608, a removable housing cover 610, and an output end 612.

[0038] Figure 6B A perspective view of a motor 602 connected to a rear end 606 according to an exemplary embodiment is depicted.

[0039] Figure 6C A perspective view depicting a pulley 608 and a hydraulic pump 604 connected to a rear end 606 according to an exemplary embodiment is shown. In some examples, the pulley 608 is configured to mechanically drive the hydraulic pump 604. In some examples, the hydraulic pump 604 is connected to a cooler configured to water-cool the electrical package during motor operation. In some examples, the pulley belt is a double-sided belt. In a further example, the pulley belt is a ribbed belt. In a further example, the pulley belt may be a flat-sided pulley belt.

[0040] Figure 6D A perspective view is depicted of a removable housing cover 610 connected to a rear end 606 and an output end 612, according to an exemplary embodiment, wherein a removable cut-out cover is installed.

[0041] In some of the embodiments described above, power take-off (PTO) is a function included in the electrical package that transmits torque from the electric motor to the auxiliary system component by rotating the shaft of the auxiliary system component. In the embodiments described above, the electrical package is designed to transfer mechanical energy from the electric motor to an external device on which the electric motor is operating.

[0042] Furthermore, in some embodiments, the electrical package may include a "clutch" mechanism that allows the output shaft of an external device (e.g., a wood chipper drum) to be disconnected from the rotary input shaft (e.g., the electrical package's motor). In other embodiments, the electrical package may include one or more mechanical adapters to drive a hydraulic pump or water pump that the external device, from which the motor is running, may require.

[0043] Figure 7A modular design of an electrical pack 700 according to exemplary embodiments is depicted. In some examples, the electrical pack may have a modular design including a battery module 702, a DC / AC inverter module 704, a motor module 706, and a mechanical module 708. The battery module 702 may include a battery pack 720, a controller display 724 with an optional onboard battery charger 716, and an optional DC / AC inverter for lower energy level charging (e.g., charging a laptop). The battery module 702 may be charged by an EV charger 710, a DC fast battery charger 712, and / or a DC motor-driven generator 714. Furthermore, the battery module 702 may be expanded with one or more additional battery packs 722 to increase storage capacity. The battery module 702 may have a DC / AC inverter output for VAC loads and / or a DC / DC inverter output for VDC loads. The battery module 702 may also include a power control unit 718.

[0044] In some embodiments, the DC / AC inverter module 704 includes a DC / AC inverter 726 and an AC load 728. Additionally, in some embodiments, the motor module 706 includes a DC / DC converter 730 and a DC motor 732. In some embodiments, the mechanical module 708 includes a shaft / pulley 734.

[0045] Figure 8 Components of an electrical pack 800 according to an exemplary embodiment are depicted. The electrical pack components may include a battery with a PDU, a motor with an inverter, an on-board battery charger, a DC / DC inverter for 12V control circuitry, a radiator with a coolant pump, telematics, a control unit for controlling MCU wake-up, DC / DC wake-up, fan / pump control, and other components that may be associated with the internal power pack. The electrical pack may also include one or more controllers for controlling the power pack and displaying key parameters and alarms, and may perform one or more processes described herein. In some embodiments, the on-board battery charger has an integrated DC / DC inverter for 12V control circuitry.

[0046] Figure 9 An electrical package 900 according to an exemplary embodiment is depicted. Figure 9 The electrical package 900 shown may be an exposed electrical package (e.g., similar to...). Figure 2 The exposed electrical package 202), and may be covered by an enclosure, for example Figure 4 The outer shell is 400.

[0047] The Electric Pack 900 can be a complete heavy-duty lithium-ion battery solution for specific applications. This power unit can be an EPA-certified pack and can be designed to be reliable, durable, and safe. The Electric Pack 900 can be equipped for applications handling essentially similar displacements to a 3.0L engine. The Electric Pack 900 may include mechanical connections (e.g., shaft / key dimensions for pulley connections).

[0048] Among other features, the Electric Pack 900 can be water-cooled and includes an electric charger to maintain a sustainably low temperature during maximum power output. Furthermore, the Electric Pack 900 may include a brushless, waterproof, high-output fan for efficient air cooling with minimal disruption to the pack layout. This fan may have a low profile, which contributes to efficient air cooling with minimal impact on the pack. Additionally, the Electric Pack 900 may have low operating noise output, allowing for extended operating hours in residential areas without disturbing the community (this may also be achieved through liquid cooling rather than mechanical cooling). Moreover, a battery-powered electric motor allows for simpler maintenance and lower maintenance costs compared to a motor.

[0049] Figure 10A An electrical package 1000 according to an exemplary embodiment is depicted. Figure 10B Depicting according to exemplary embodiments Figure 10A The casing of the Zhongdianbao 1000. Figures 10A-10B The electrical package 1000 shown may include exposed electrical packages (e.g., similar to...). Figure 2 The exposed electrical package 202 and Figure 9 The exposed electrical package (900) can be covered by an enclosure, for example... Figure 4 The outer casing 400, such as Figure 10B As shown. Electrical package 1000 may include any components of the aforementioned electrical package.

[0050] Figure 11A An exposed electrical package 1100 is depicted according to an exemplary embodiment. Figure 11B Depicting according to exemplary embodiments Figure 11A An exploded view of the exposed electrical package 1100. The electrical package 1100 may include any components of the aforementioned electrical package. For example, such as... Figure 11A-11B As shown, the electrical package 1100 may include a battery pack 1102, a power distribution unit (PDU) 1104, a DC / AC inverter 1106, a motor and power output (PTO) 1108, a water-cooled or air-cooled battery charger 1110, a radiator and water pump 1112, a controller 1114, and a base, slide, or other mechanical means for integrating the components together to form a plug-and-play package 1116. In some embodiments, the above components may be combined and assembled to form a package such as Figure 11A The electrical package shown is 1100.

[0051] Figure 12 Components of an electrical package according to an exemplary embodiment are depicted. The electrical power package 1200 may include any of the components described above. For example, such as... Figure 12 As shown, the electrical power package 1200 may include a CCS connector 1202, a J1772 connector 1204, an on-board battery charger 1206, an HV connector LV and a control connector coolant connection 1208, a motor 1210, a pump 1212, a radiator 1214, a 12VDC battery 1216, a PDU 1218, a battery pack (primary) 1220, a control unit 1222, a display 1224, a telematics unit 1226, a DC / AC inverter 1228, a socket 1230, and a battery pack (secondary) 1232. In other embodiments, the electrical power package 1220 may not include... Figure 12 The components may be optional, such as the HV connector LV and control connector coolant connection 1208, telematics 1226, DC / AC inverter 1228 and socket 1230, and battery pack (sub) 1232. Additionally, connections 1234 may exist between two or more components in the electrical power package 1200.

[0052] Figure 13 A rear end 1300 is depicted connecting to the motor 1304 and the output shaft 1308. In some examples, the output shaft 1308 is configured to connect to an external device. The housing may also include a removable housing cover 1314 configured to cover the pulleys and connect to the output shaft mount 1306. In some examples, the motor 1304 is configured to connect to the output end via a hand-operated key. The housing may also include a mounting pad and bracket 1312 configured to mount the housing onto the frame of the electrical package. The mounting pad and bracket 1312 is distinct from the mounting pad and bracket.

[0053] In a first embodiment, an electrical package includes at least one battery, at least one electric motor, a battery charger for charging the at least one battery, a power converter, a cooling system, and a control system including at least one processor and a non-transitory computer-readable medium.

[0054] In a second embodiment, a method includes: determining, by at least one processor, whether to activate a power converter of an electrical pack, wherein the electrical pack includes at least one battery, at least one electric motor, a battery charger for charging the at least one battery, the power converter, a cooling system, and a control system including the at least one processor and a non-transitory computer-readable medium, wherein instructions are stored on the non-transitory computer-readable medium; and determining, by the at least one processor, whether to activate the cooling system of the electrical pack.

[0055] II. Conclusion

[0056] It should be understood that the arrangements described herein and / or illustrated in the accompanying drawings are for illustrative purposes only and are not intended to be limiting. Therefore, those skilled in the art will understand that other arrangements and elements (e.g., machines, interfaces, functions, sequences, and / or functional groupings) may be used, and some elements may be omitted entirely.

[0057] While various aspects and embodiments have been described herein, other aspects and embodiments will be apparent to those skilled in the art. The aspects and embodiments disclosed herein are for illustrative purposes only and are not intended to be limiting; the true scope is indicated by the claims and the full scope of their equivalents. It should also be understood that the terminology used herein is for descriptive purposes only and is not intended to be limiting.

[0058] In this specification, the articles "a," "an," and "described" are used to describe elements and / or functions of exemplary embodiments. The intent of using these articles is that one or more of the described elements and / or functions are present.

[0059] In this specification, the use of the term "and / or" in a list of at least two elements or functions, and the use of the terms "at least one of them," "at least one of the following," "one or more," "one or more from among them," and "one or more of the following" immediately before a list of at least two components or functions, is intended to cover each embodiment that includes each of the listed components or functions, as well as each embodiment that includes a combination of the listed components or functions. For example, embodiments described as including A, B, and / or C, or at least one of A, B, and C, or at least one of A, B, and C, or at least one of A, B, or C, or at least one of A, B, or C, or one or more of A, B, and C, or one or more of A, B, and C, or one or more of A, B, or C, are intended to cover each of the following possible embodiments: (i) embodiments including A but not including B and C, (ii) embodiments including B but not including A and C, (iii) embodiments including C but not including A and B, (iv) embodiments including A and B but not including C, (v) embodiments including A and C but not including B, (v) embodiments including B and C but not including A, and / or (vi) embodiments including A, B, and C. For embodiments including component or function A, the embodiment may include one or more A's. For embodiments including component or function B, the embodiment may include one or more B's. For embodiments including component or function C, the embodiment may include one or more C's. Based on the above examples and at least some exemplary embodiments, "A" may represent a component, "B" may represent a system, and "C" may represent a symptom.

[0060] The use of ordinal numbers such as "first," "second," and "third" is to distinguish the corresponding elements, not to indicate the order of these elements, unless the context in which these terms are used explicitly states otherwise. Furthermore, the description of a "first" element (e.g., the first plate) does not require the existence of a second or any other element (e.g., the second plate).

Claims

1. An electrical package, comprising: At least one battery; At least one electric motor; A battery charger for charging the at least one battery; Power converter; Cooling system; as well as A control system including at least one processor and a non-transitory computer-readable medium.

2. The electrical package of claim 1, wherein the non-transitory computer-readable medium stores instructions that, when executed by the processor, cause the processor to perform one or more operations.

3. The electrical package of claim 2, wherein the cooling system includes a radiator.

4. The electrical package of claim 3, wherein the radiator includes a coolant pump.

5. The electrical package of claim 4, wherein the one or more operations include: Determine whether to start the power converter; as well as Determine whether to start the coolant pump.

6. The electrical package of claim 2, wherein the cooling system includes a fan.

7. The electrical package according to claim 1, further comprising: Remote information processing.

8. The electrical package according to claim 1, further comprising: An inverter, wherein the inverter is built into the at least one motor.

9. The electrical package according to claim 1, further comprising: Color thin-film transistor liquid crystal (TFT LCD) display.

10. The electrical package of claim 1, further comprising: Remote monitoring system.

11. The electrical package according to claim 1, further comprising: A housing, wherein the housing includes a battery mounting portion configured to mount the at least one battery and a motor mounting portion configured to mount the at least one motor.

12. The electrical package of claim 11, wherein the housing includes a base, wherein the base includes one or more slots, and wherein the one or more slots are configured to receive part of a forklift.

13. The electrical package of claim 11, wherein the housing includes one or more ventilation areas, and wherein the battery mounting portion of the housing excludes the one or more ventilation areas.

14. The electrical package of claim 11, wherein the housing includes one or more shock absorbers.

15. The electrical package of claim 11, wherein the housing includes one or more service doors through which the at least one battery can be accessed.

16. The electrical package of claim 1, further comprising: A rear end connected to the at least one motor, the rear end comprising: rear housing; and The pulley within the rear housing is connected to the hydraulic pump; and Mechanical output.

17. The electrical package of claim 16, wherein the mechanical output is configured to be connected to an external device.

18. The electrical package of claim 17, wherein the external equipment comprises at least one of the following: a water pump, a vacuum cleaner, a water sprayer, an air compressor, a wood chipper, and a stump grinder.

19. The electrical package of claim 17, wherein the rear housing includes a removable rear housing cover, wherein the removable rear housing cover is configured to connect to a mounting base of the mechanical output, and wherein the removable rear housing cover is configured to cover the pulley.

20. A method comprising: At least one processor determines whether to activate the power converter of the electrical package, wherein the electrical package includes: At least one battery, At least one electric motor, A battery charger for charging the at least one battery. The power converter, Cooling system, and A control system including the at least one processor and a non-transitory computer-readable medium, wherein the non-transitory computer-readable medium has instructions stored thereon; and The at least one processor determines whether to activate the cooling system of the electrical package.

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