Payload carrier

Abstract

A payload carrier (10), comprising a support subassembly (20) and an integrated tray arrangement (12). The support subassembly (20) is fixed to, extends from and / or is suspended from the integrated tray arrangement (12). The integrated tray arrangement (12) forms part of a structural chassis of the payload carrier (10) and is therefore designed to support the payload carrier (10) and to increase bending stiffness, torsional stiffness and impact strength of the payload carrier (10). Typically, the integrated tray arrangement (12) comprises a tray (14) and a support structure (18).

Description

[0001] PAYLOAD CARRIER

[0002] BACKGROUND TO THE INVENTION

[0003] This invention relates to the field of hauling, carrying, conveying and / or transporting of payloads. The invention extends to various forms of payloads. In one embodiment, the invention extends to the field of raw material handling, and particularly, to vehicles used in the process of hauling, carrying, conveying and / or transporting such raw materials. In other examples, the payload may be goods, people or livestock and the like. Generally, the present invention relates to relatively low-weight structures of vehicles used in the hauling, carrying, conveying and / or transporting of payloads, though the invention is not specifically limited to use with vehicles, and other forms of structures of containers or carriers are also provided for. The invention also extends to a method of designing such low-weight structures.

[0004] Increased focus on energy efficiency and environmental impact in the hauling, carrying, conveying and / or transporting industry, call for efficiency improvements in in terms of energy expenditure of vehicles. To this end, focus is shifting towards smaller and more efficient vehicles (smaller in this case facilitates implementation of more energy efficient technologies, greater autonomy and, in some cases, renewable energy). Furthermore, a focus is also placed on improvements in terms of energy efficiency of surrounding systems and processes to result in a holistic focus on energy expenditure and efficiency. For example, vehicles driven by renewable sources such as electricity or hydrogen could potentially provide a means of utilising “clean” energy in the hauling, carrying, conveying and / or transporting process. However, these vehicles’ range is heavily dependent on the weight of the vehicle.

[0005] One aspect that contributes significantly to the weight of conventional haul, carry, convey and / or transport vehicles, is the weight associated with structural components such as a chassis, undercarriage, suspension system and the like. Typically, these components have substantial weights necessitated by an ability to withstand typical loads, shocks, vibrations, fatigue, and the like, encountered as a result of the size of the load carried by the vehicle and the environment in which the vehicle operates.

[0006] In many cases, passenger vehicles make use of so-called monocoque construction, which incorporates structural components of a vehicle into its body or shell. This is possible due to the relatively low size of loads carried by these kinds of vehicles and results in significant weight saving. To date, however, the use of monocoque construction is limited. For example, higher performance passenger vehicles such as sport vehicles, off-road vehicles, pickup trucks and the like, which are associated with higher stresses and loads, typically still make use of ladder frame or body-on-frame construction, to handle loads associated with use of the vehicle adequately. The incorporation of monocoque construction in larger haul, carry, convey and / or transport vehicles remains unexplored. Implementation of alternative low-weight construction methods for structural components of hauling, carrying, conveying and / or transporting equipment has also, to date, been lacking.

[0007] It is believed that a reduction in the total weight of a vehicle could have a profound impact on the overall energy expenditure associated with hauling, carrying, conveying and / or transporting of payloads. This includes reducing an empty weight of the vehicle relative to its payload. It is believed that the use of such lower weights will be associated with increased productivity, operational flexibility and overall efficiency.

[0008] Again, it is believed that a reduction in the overall weight of the structural components, could bring same into an order more suitable for use of alternative, environmentally efficient and / or renewable energy resources.

[0009] It is accordingly an object of the invention to provide a payload carrier that will, at least partially, address the above disadvantages or facilitate the above potential improvements.

[0010] It is also an object of the invention to provide a payload carrier which will be a useful alternative to existing payload carriers.

[0011] SUMMARY OF THE INVENTION

[0012] In accordance with a first aspect of the invention there is provided a payload carrier, comprising: a support subassembly; and an integrated tray arrangement, wherein the support subassembly is fixed to and / or extends from the integrated tray arrangement and wherein the integrated tray arrangement forms part of a structural chassis of the payload carrier.

[0013] The integrated tray arrangement may comprise a tray and a support structure. The tray may operatively interact with the support structure to facilitate transfer of loads between the support structure and the tray. The support structure may be situated towards an outside of the tray. The support structure may be manufactured from a polymeric composite material or a metal, such as steel, stainless steel or aluminium. The support structure may be designed and / or shaped based on an analysis-led design approach.

[0014] The support structure may take the form of an exoskeleton forming a cradle within which the tray is received or may be integrally formed with the tray. The support structure may comprise at least a first peripherally extending member. The peripherally member may be located peripherally about an open top portion of the tray. The support structure may furthermore include longitudinal ribs extending at least partially underneath the tray and supporting the tray from below. In some examples, the support structure may include at least two central longitudinal ribs and two outer longitudinal ribs. The longitudinal ribs may extend between opposing portions of the peripherally extending member and, in some cases, the longitudinal ribs may be fixed to or integrally formed with the peripherally extending member.

[0015] A periphery of an open-ended top of the tray may be reinforced by a rim arrangement, comprising a single rim section or a plurality of interlocking rim sections.

[0016] The support structure may, in some examples, comprise a plurality of cross-extending members and interconnecting members.

[0017] The support structure may further comprise a first and second subframe extending relative to the tray in a forward and rearward direction, respectively. The support structure may further comprise forward-extending and rearward-extending shear panels. The shear panels may extend in a plane substantially parallel to a surface on which the payload carrier is operatively supported. The shear panels may be substantially trapezoidal viewed from the top. The shear panels may have a thickness in the range of 2mm to 6mm, preferably about 4mm. The shear panels may be manufactured from a metal or a composite material. The shear panels may be fixed directly or indirectly to the tray.

[0018] The payload carrier may comprise at least a first external anchoring arrangement extending beyond an outer surface of the tray. The external anchoring arrangement may comprise an external plate and a backplate. A portion of the external anchoring arrangement may extend at least partially through the tray and between the external plate and backplate, to sandwich the tray between the external plate and backplate. The external plate and / or backplate may be bonded to the tray. The external anchoring arrangement may be manufactured from a metal such as steel or stainless steel. The external anchoring arrangement may be fixed relative to the support structure.

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

[0020] The tray may have a shape which is either U-shaped in cross-section or substantially hemispherical. The tray may define a trough portion and sidewall portions. A wall thickness of the trough portion may exceed a wall thickness of the sidewall portions, thereby to increase bending stiffness, torsional stiffness and impact strength of the trough portion. The wall thickness of the sidewall portions may be in the range of 4mm to 12mm, preferably equal to about 8mm. The wall thickness of the trough portion may be in the range of 8mm to 20mm, preferably about 12mm. The tray may be manufactured from metals, such as steel, stainless steel and aluminium; composite materials; or a layered material, comprising at least one metal layer and one composite layer.

[0021] The tray may comprise a plurality of tray layers, at least one of which may be manufactured from a composite material. The tray may be designed and / or shaped in accordance with an analysis-led design approach.

[0022] In one example, the payload carrier has tray layers which include: a main tray layer; and a liner layer received over the main tray layer.

[0023] The main tray layer may comprise a steel layer or a polymeric layer. The liner layer may comprise a single-piece moulded layer; ii) a layer sprayed onto the main tray layer; iii) a layer cast onto the main tray layer; or iv) a layer made up of adjoining bolted sections. The liner layer may comprise a steel layer or a polymeric layer. The polymeric layer may comprise a fibre-reinforced polymeric layer, the fibre of the fibre-reinforced polymeric layer comprising a glass-fibre, carbon fibre or natural fibre.

[0024] An operatively bottom portion of the main tray layer may comprise a locally thickened wall portion. A strike plate may optionally be sandwiched between operatively bottom portions of the tray layer and the liner layer.

[0025] An outer surface of the tray may be lined with individual protective armour panels manufactured from metal such as steel, stainless steel or aluminium, or composite materials.

[0026] The integrated tray arrangement may have an open-ended top configured to receive the payload therethrough. Typically, the payload takes the form of raw material.

[0027] The integrated tray arrangement may include a measuring sensor to measure stress, strain, acceleration, temperature, or vibration. The measuring sensor may comprise a strain gauge, accelerometer or thermocouple.

[0028] The integrated tray arrangement may have a roof portion and a closable opening configured as a door.

[0029] In accordance with a second aspect of the invention there is provided a heavy-duty vehicle, comprising a frame manufactured from a composite material and shaped and designed based on an analysis-led design approach.

[0030] Further in accordance with the second aspect of the invention, the frame may be manufactured from a polymeric material in the form of a fibre-reinforced polymeric material. The fibre comprises a glass-fibre, carbon fibre or natural fibre.

[0031] The frame may comprise an integrally formed lattice structure. The frame may be formed through or by means of a moulding process. The frame may comprise hollow frame members formed by foam inserts provided in a mould used during the moulding process.

[0032] The frame may include one or more measuring sensors to measure stress, strain, acceleration, temperature, and / or vibration exerted on or experienced by frame. The measuring sensor may comprise of a strain gauge, accelerometer and / or thermocouple.

[0033] BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The invention will now be described in more detail, by way of example only, with reference to the accompanying drawings in which:

[0035] Figure 1 shows a front perspective view of a payload carrier in accordance with a first nonlimiting example embodiment of the invention;

[0036] Figure 2 shows a perspective view of an integrated tray arrangement forming part of the payload carrier of Figure 1 , wherein a tray of the integrated tray arrangement has been partially sectioned;

[0037] Figure 3 shows a detailed perspective view of a fixing arrangement associated with the tray of the integrated tray arrangement of the payload carrier of Figure 1 ;

[0038] Figure 4 shows a backplate of the fixing arrangement of Figure 3, which is situated towards an inside of the tray of the payload carrier of Figure 1 ;

[0039] Figure 5 shows a perspective view of an alternative embodiment of an integrated tray arrangement of the payload carrier of Figure 1 , wherein the tray has, again, been partially sectioned to reveal internal layers thereof and includes detailed views of some of the partially sectioned parts;

[0040] Figure 6 shows a perspective view of yet a further alternative embodiment of an integrated tray arrangement forming part of the payload carrier of Figure 1 , wherein the integrated tray arrangement has been partially sectioned;

[0041] Figure 7 shows a detailed view of a fixing arrangement associated with the example embodiment of the integrated tray arrangement of Figure 6;

[0042] Figure 8 shows a simplified front perspective view of a payload carrier in accordance with a second non-limiting example embodiment of the invention, the payload carrier shown in an unloaded or empty state;

[0043] Figure 9 shows a simplified front perspective view of the payload carrier of Figure 8, after having been loaded with raw material;

[0044] Figure 10 shows a front perspective view of a payload carrier in accordance with the second non-limiting example embodiment of the invention, the payload carrier shown in use while carrying a payload in the form of raw material such as an excavated ore; Figure 11 shows a perspective view of the payload carrier of Figure 10 with lateral doors thereof in an open configuration to allow operative unloading of the payload;

[0045] Figure 12 shows a side view of the payload carrier of Figure 10;

[0046] Figure 13 shows a front view of the payload carrier of Figure 10;

[0047] Figure 14 shows a top perspective view of an integrated tray arrangement which forms part of the payload carrier of Figure 10;

[0048] Figure 15 shows a bottom perspective view of the integrated tray arrangement of Figure 14;

[0049] Figure 16 shows a top view of the integrated tray arrangement of Figure 14; and

[0050] Figure 17 shows a bottom perspective view of the integrated tray arrangement of Figure 14 and support subassemblies including suspension subassemblies forming part of a drivetrain of the payload carrier;

[0051] Figure 18 shows a schematic top perspective view of a heavy-duty vehicle in accordance with the invention; and

[0052] Figure 19 shows a bottom perspective view of the heavy-duty vehicle of Figure 18.

[0053] DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

[0054] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of "including," "comprising," or "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms "mounted", "connected", "engaged" and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings and are thus intended to include direct connections between two members without any other members interposed therebetween and indirect connections between members in which one or more other members are interposed therebetween. Further, "connected" and "engaged" are not restricted to physical or mechanical connections or couplings. Additionally, the words "lower", "upper", "upward", "down" and "downward" designate directions in the drawings to which reference is made. The terminology includes the words specifically mentioned above, derivatives thereof, and words or similar import. It is noted that, as used in this specification and the appended claims, the singular forms "a," "an," and "the," and any singular use of any word, include plural referents unless expressly and unequivocally limited to one referent. As used herein, the term “include” and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items.

[0055] Referring to the drawings, in which like numerals indicate like features, a payload carrier (or just “carrier”) in accordance with the invention is generally referred to by reference numeral 10 while a first non-limiting example of the carrier is indicated by reference numeral 10.1 in the figures and a second non-limiting example of the carrier is indicated by reference numeral 10.2 in the figures. It will be appreciated that features described in relation to one non-limiting example may be compatible and interchangeable with another non-limit example unless stated otherwise.

[0056] The payload carrier 10 may take a vast number of forms and is not limited to the examples shown in the figure or discussed herein.

[0057] In general terms, the carrier 10 comprises a support subassembly 20 and an integrated tray arrangement 12. The support subassembly 20 is fixed to and / or extends or is suspended from the integrated tray arrangement 12. Furthermore, the integrated tray arrangement 12 forms part of or represents a structural chassis of the carrier 10. In some cases, the integrated tray arrangement 12 comprises a tray 14 and a support structure 18.

[0058] The tray 14 defines a volume 16 in which a payload 19 (as shown in figure 10) is received in use. The support structure 18 is situated or formed towards an outside of the tray 14. The support structure 18 may take various forms, some of which are described below. In some cases, the support structure 18 may be omitted, and structural integrity of the integrated tray arrangement 12 may be provided by the specific construction of the tray 14, as discussed below.

[0059] Since the tray 14 forms part of the integrated tray arrangement 12, the tray 14 is configured to provide structural integrity, rigidity and support to the payload carrier 10. For example, the tray 14 is configured to provide torsional and bending stiffness to the integrated tray arrangement 12. This is achieved by the design of the tray 14 and more particularly, by material selection and the shape and configuration of the tray 14. This is discussed more fully below.

[0060] The carrier 10 shown in the figures takes the form of a haul carrier, and the tray 14 has an open-ended top 26 for receiving the payload 19, which typically takes the form of raw material such as rock fragments or excavated ore.

[0061] In some examples, the tray 14 and support structure 18 are manufactured from a metal, such as steel, stainless steel or aluminium. The use of metal in the manufacture of the tray 14 and support structure 18 is advantageous due to a low cost, ability to withstand penetration and the stiffness thereof. However, metal does, in some cases, cause relatively high impact loads to be transferred to other parts of the structural chassis. In other examples, both the tray 14 and support structure 18 are manufactured from a composite material. A combination of metal and composite materials in the manufacture of the tray 14 and support structure 18 would theoretically be feasible.

[0062] For the present purposes, a “composite material” will be understood to refer to a material made up of various types of materials, of which at least some of the materials are polymeric, non- metallic materials. In some cases, the composite material may include metallic constituents, inserts or reinforcements. Typically, the composite material includes glass, carbon or natural fibre composite materials, the use of which is advantageous due to the relatively low weight associated therewith. That said, glass, carbon or natural fibre composite materials are typically more brittle than steel.

[0063] In yet a further alternative example, some implementations of which are discussed more fully below, the tray 14 is manufactured from a layered or sandwiched material. In some cases, some of the layers may comprise metal layers. Such layered materials combine stiffness and energy absorption capabilities of steel with lowered load and impact distribution to the rest of the integrated tray arrangement 12. However, costs associated with the layered materials are higher than those of stand-alone metals or composites.

[0064] The integrated tray arrangement 12 is designed in accordance with an analysis-led design approach or methodology, which revolves around the principle of configuring the integrated tray arrangement 12, or just the tray 14 when relevant, based on the one hand, on load paths associated with forces exerted on the carrier 10, but on the other hand, also on the results of in- use load-case, impact, wear and abrasion testing. Furthermore, components or portions of the integrated tray arrangement 12 are selected with both of these aspects in mind. For example, in the present example, one of the load cases designed for relates to the loads associated with forces exerted by the payload on the tray 14, which relates to the physical weight of the payload. Another load case relates to point loads transferred to the tray 14 by rock fragments, wear caused by displacement of the payload relative to the tray 14 during loading or use, cyclic strains and vibrations caused during loading, unloading and normal operation, and the like. The analysis-led design approach or methodology therefore entails an integrated approach when it comes to sizing of components and material selection. It views different parts of the integrated tray arrangement 12 in isolation and prescribes specific sizing and material selection based on the aforementioned analysis to result in a holistic or global efficiency from a load carrying, fatigue life and weight point of view. For example, even though certain parts of the integrated tray arrangement 12 may be manufactured from materials with greater wear resistance properties, such parts and materials are still considered from a load carrying capability. An adjacent area may see lower abrasion and fatigue and may therefore be manufactured from another material with more advantageous weight properties, or the like. This approach should be contrasted with conventional design methodologies, where different load scenarios are viewed in isolation. For example, conventionally, a conventional design methodology would entail designing for a load carrying capability on the one hand, and in isolation, considering aspects such as wear and abrasion or impact absorption, and providing secondary materials such as liners, or secondary components, such as dampers, to address this. By looking at these aspects in isolation, a design obtained using conventional methods may be less efficient, heavier and more expensive.

[0065] The frame may typically take the form of an interconnected or unitary lattice structure and may be made up of a number of components or subassemblies.

[0066] Importantly, the tray 14 and support structure 18 interact to transfer loads therebetween to enable both to contribute to the structural integrity of the integrated tray arrangement 12. In some cases, parts of the support structure 18 may be fixed to the tray 14, such as by way of welding or bonding. In other examples, the tray and support structure may be integrally formed.

[0067] In the example shown in figures 1 and 2, the support structure 18 is formed as an exoskeleton, which is manufactured separate from the tray 14. Here, the support structure 18 forms a cradle within which the tray 14 is received and supported. The tray 14 may therefore rest on top of the support structure 18. Even though separately manufactured, the support structure 18 and tray 14 may be joined together by bonding, the use of mechanical fasteners, or the like.

[0068] In the example shown in figures 6 and 7, the support structure 18 is integrally formed with the tray 14, and therefore extends from the outer surface 36 of the tray 14. In this example, the frame is manufactured from the same material as the outer tray layer 24 (and particularly, the composite polymeric material).

[0069] The support structure 18 comprises a first peripherally extending member, hoop member or top frame 44 which extends around the tray close to or at the periphery 40 and provides circumferential and peripheral support to the tray 14. The peripherally extending member 44 comprises a structure with a closed shaped and upper parts of the tray 14 may be fixed to parts of the peripherally extending member. The peripherally extending member 44 lends tortional stiffness to the integrated tray arrangement 12 whilst reinforcing and protecting edges of the tray 14 (particularly during loading).

[0070] The peripherally extending member 44 is typically manufactured from a single or a number of interconnected beam members and is typically manufactured from a material similar to that of the tray 14.

[0071] In some cases, as shown in figures 1 , 2, 6 and 7, the support structure 18 also includes a number of further cross-extending members 46 and interconnecting members 48. The support structure 18 furthermore includes a number of longitudinal ribs (generally indicated by reference numeral 74). These extend underneath the tray 14 and supports the tray 14 from below. The longitudinal ribs 74 primarily counteracts bending stresses encountered by the tray 14, but also improves torsional stiffness of the integrated tray arrangement 12.

[0072] With specific reference to figures 10 to 17, the carrier 10.2 typically includes two central longitudinal ribs (indicated by reference numeral 74.1 ) and two outer longitudinal ribs (indicated by reference numeral 74.2). The central longitudinal ribs 74.1 extend from, and are fixed to or integrally formed with, the top frame 44. In some cases, the outer longitudinal ribs 74.2 also extend from, and are fixed to or integrally formed with, the top frame 44. However, in some examples (not shown), the outer longitudinal ribs 74.2 only extend about the trough portion (as discussed below) of the tray 14.

[0073] Also with specific reference to figures 10 to 17, the support structure 18 furthermore includes a front shear panel 76.1 and rear shear panel 76.2. The shear panels 76 extend in a forwards and rearwards direction of the carrier 10.2 respectively and extend substantially parallel to a surface on which the carrier 10 is operatively supported. Inward-facing edges of the shear panels 76 are fixed, directly or indirectly, to the upper edges of the tray 14. By being fixed relative to the tray, and by extending in a plane with which the tray 14 is not coincident, the shear panels add stiffness, rigidity and structural integrity to the integrated tray arrangement 12. In fact, it has been found that the inclusion of the shear panels may increase stiffness of the integrated tray arrangement 12 by as much as 29%.

[0074] The shear panels 76 are supported by shear panel support beams 78.

[0075] The shear panels 76 also perform a secondary function by shielding and protecting components of the drivetrain (such as motors, batteries, cooling systems and the like) from falling rocks and debris. Parts of the shear panels 76 may taper slightly to the sides to prevent rocks and debris from accumulating thereon.

[0076] The shear panels 76 may typically have a thickness of about 4mm.

[0077] The integrated tray arrangement 12 furthermore includes first and second subframes 80 which support the drivetrain, serve as storage compartments for drivetrain components and lend further structural rigidity to the integrated tray arrangement 12. The subframes 80 may typically comprise box frames.

[0078] The support structure 18 therefore provide support to various components of the carrier 10. For example, suspension subassemblies 58 may be mounted to the longitudinal ribs 74 and / or subframes 80, while various drivetrain components may be mounted to and supported by the shear panel support beams 78 and subframes 80. Generally, the tray 14 is substantially U-shaped in cross section. As shown in the figures, the first non-limiting example comprises a substantially hemispherical, concave or bowl-shaped tray 14. This shape provides an advantageous stress distribution and relatively evenly distributed hoop stresses. The second non-limiting example comprises a tray 14 which is substantially U- shaped viewed from the side.

[0079] Reference is now made specifically to the first non-limiting example of figures 1 to 7. As best shown in figure 5, the tray 14 is manufactured from a composite material, has a composite construction, and comprises a number of layers of material. Figure 5 is sectioned along various lines to selectively reveal some of these layers.

[0080] The tray 14 firstly comprises a main or outer tray layer 24, which is typically manufactured from a polymeric material (though manufacturing same from a metal such as steel could in some examples be feasible). Towards a bottom portion 28 of the tray 14, the main tray layer 24 has a locally thickened wall portion 30, which aids and facilitates withstanding of impacts caused when the payload is received (or rather dumped) into the volume 16 through the open-ended top 26.

[0081] The tray 14 also comprises a liner layer 32 which is provided over the main tray layer 24, towards an inside of the tray 14. The liner layer 32 provides further strength and wear resistance to the tray 14. The liner layer may take one of the following forms (non-exhaustive):

[0082] - a single-piece moulded layer (typically a polymeric material);

[0083] - a layer sprayed onto the main tray layer (typically a polymeric material);

[0084] - a layer cast onto the main tray layer (typically a polymeric material); or

[0085] - a layer made up of adjoining bolted sections (typically a metallic layer, though polymeric sections could also be used).

[0086] The use of one of the first three iterations of the liner layer 32 is particularly beneficial from a waterproofing point of view and inhibits ingress of water, dust and other foreign matter between the layers of the tray 14.

[0087] The use of the last iteration of the liner layer 32, namely the layer made up of adjoining bolted sections, on the other hand, provides a useful means of enabling the replacement of single worn-out or damaged sections of the liner layer 32.

[0088] A liner layer comprising a combination of two or more of these iterations would be feasible.

[0089] A metallic (steel or stainless steel) strike plate 34 is situated towards the bottom portion 28 of the tray 14 and is sandwiched between the outer tray layer 24 and the liner layer 32. Again, the strike plate 34 is provided to withstand impacts caused when the payload is received (or rather dumped) into the volume 16 through the open-ended top 26.

[0090] In some cases, an outer surface 36 of the tray 14 is lined with a layer of protective armour panels 38, which are again individually replaceable, in case of damage or wear. Typically, the panels are manufactured from steel. The panels 38 are arranged in adjacent fashion and are provided to interlock with each other (such as by use of lap joints or tongue and groove joints). The panels 38 may serve to protect the tray 14 against impacts and abrasion but may also lend structural rigidity and stiffness to the tray 14. The panels may be secured relative to the tray 14 by bolts or other suitable fastening mechanisms.

[0091] A periphery 40 of the open-ended top 26 is reinforced by a metallic rim arrangement 42. The rim arrangement 42 typically takes the form of a number of interlocking metallic rim sections, which are clamped in position relative to the tray 14. The rim arrangements 42 are provided to protect the tray 14 against abrasion and impacts caused during loading and / or unloading of the payload through the open-ended top 26.

[0092] The carrier includes strategically placed external fixing / connecting / anchoring arrangements 50. In some cases, such as the example shown in figure 7, the fixing arrangement 50 is fixed to or supported by the support structure 18 directly. The fixing arrangement 50 may, in this case, be bonded to the support structure 18, or may alternatively be fixed thereto by means of mechanical fasteners such as bolts and nuts.

[0093] In other examples as shown in figures 3 and 4, the fixing arrangements 50 comprise an external plate 52, backplate 54 and fixing point 56. The external plate 52, backplate 54 and fixing point 56 are all manufactured from steel or stainless steel. The backplate 54 is arranged towards an inside of the volume, and the tray 14 is therefore sandwiched and clamped between the external plate 52 and the backplate 54. The fixing point 56 extends beyond the outer surface 36 of the tray 14.

[0094] The locations of the fixing arrangements 50 are considered when determining load paths when designing the support structure 18, as aforementioned. The fixing arrangements 50 are typically provided for fixing the support subassembly 20 relative to the tray 14.

[0095] Bonding of the fixing arrangements 50 provide a beneficial mechanism for load distribution associated with the fixing arrangements 50.

[0096] Reference is now made specifically to the second non-limiting example of figures 8 to 17. Here, the tray 14 includes laterally opening doors 82 which facilitate unloading of the payload 19, thus eliminating the need for alternative on-board unloading hardware, such as tilting equipment or the like.

[0097] The U-shaped tray 14 is particularly suited to withstand hoop stresses.

[0098] The tray 14 defines a lower or trough portion 84 and sidewall portions 86. Load cases experienced by these different portions differ slightly. For example, the trough portion 84 sees higher impact, tortional and bending stresses than the sidewall portions 86. As a result, the different portions (84, 86) have different wall thicknesses, which are selected based on typical loads carried and experienced by these portions of the tray (an example of the analyses-led design approach).

[0099] The trough portion 84 is reinforced to be able to withstand impacts typically encountered during loading of the tray (caused by, for example, rocks falling into the tray 14 from a loading height). The trough portion 84 typically has a wall thickness of about 12 mm, even though the wall thickness may typically be between about 8mm and 26mm.

[0100] Due to the tapering of the sidewall portions 86, impacts encountered during loading of raw materials are typically lower than the impacts encountered by the trough portion 84. Because of this and lower bending stresses, the wall thickness of the sidewall portions 86 is lower than that of the trough portion 84. Typically, the sidewall portions 86 have a wall thickness of about two- thirds that of the trough portion 84. Therefore, the wall thickness of the sidewall portions 86 is typically around 8mm, even though this may typically be between 6mm and 12mm.

[0101] In addition to an improved ability to withstand impacts encountered during loading, the increased wall thickness of the trough portion 84 provides for improved bending and torsional stiffness. Furthermore, even though of lesser wall thickness, the sidewall portion 86 still contributes to the structural integrity of the tray 14. However, since smaller loads are encountered by the wall portions 86, a thinner wall thickness is still sufficient to provide structural integrity, whilst facilitating a reduction in overall weight of the tray 14. The design of the tray therefore ensures an ability of the tray 14 to serve an integral part of the integrated tray arrangement 12.

[0102] The support subassembly 20 typically comprises suspension 58 components, drivetrain components such as motors, gearboxes, fuel systems, batteries and the like (not shown), wheels 60 (which could be replaced by tracks) and the like. At least some of the wheels 60 may be driven. Alternatively, the haul carrier may be a trailer.

[0103] The suspension system 58 may be fixed to parts of the support structure 18, or where relevant, to the fixing arrangements 50, which are affixed relative to the tray 14. It will again be appreciated that the integrated tray arrangement 12 plays an integral part in the structural integrity of the carrier 10, and as a result, a conventional ladder frame arrangement which would typically be required to support a suspension arrangement of the vehicle, may, at least to a large degree, be eliminated, contributing to a reduced overall vehicle mass.

[0104] The composite structures of the carrier 10 are designed to be protected from damage caused by wear and impacts. The liner layer 32 and external armour panels 38 are examples of mechanisms provided for protecting against wear (and to a degree, impacts). The thickened portions 30 and strike plate 34 are examples of mechanisms provided for protecting against impact damage. Again, as mentioned, the specific configuration and use of such protective measures are informed by specific load cases / scenarios, predetermined impact and load points and load shapes. The specific configuration of such protective measures is, as mentioned, designed and specified based on an analysis-led process. However, providing such mechanisms and measures enables the use of the carrier, and particularly the composite materials used in its construction, in heavy duty applications, such as mining and / or material hauling. Providing these mechanisms and measures therefore facilitates use of composite materials and realising the advantages associated therewith.

[0105] It is believed that the use of the tray 14 as part of the integrated tray arrangement 12 of the carrier 10, and particularly, to assist in withstanding loads and stresses, enables the overall weight of the vehicle to be reduced, resulting in a lower vehicle weight to payload ratio. Such a reduction in vehicle weight is associated with increased efficiency of the haul vehicle and the overall earthmoving operations. It will be appreciated that the use of the tray 14 as a structural component forming part of the integrated tray arrangement 12 enables a reduced need for structural frames, such as stand-alone ladder frames and the like. Furthermore, the support structure (forming part of the integrated tray arrangement 12) may specifically be designed to provide reinforcement in addition to or to supplement the support and structural integrity already provided by the tray 14. In this way, a more efficient use of the support structure may be facilitated.

[0106] Furthermore, sensors, such as strain gauges, accelerometers and the like may be ingrained or implanted into structural components. This may provide the ability to monitor, in real time or historically, data relating to loading, including shock loading and vibrations and the like, experienced by the frame. This data may be used in the further optimisation of the structural components using the load path methodology but may also be used to manage preventative maintenance of the vehicles. Again, the modularity and replaceability of components means that components close to failure may easily be replaced with new components.

[0107] The invention furthermore extends to a heavy-duty vehicle 70 with a frame 72 or other structural components which is manufactured according to the analysis-led design methodology detailed above. The heavy-duty vehicle schematically shown in figures 18 and 19 comprises a tipper truck used for hauling raw material. However, it will be appreciated that the heavy-duty vehicle 70 may take various forms, such as excavators and other earth-moving machinery used in mining and construction and may furthermore include road going vehicles such as trucks, buses and the like. It will be appreciated that the heavy-duty vehicle need not necessarily be associated with a tray 14, and the load paths used to design the frame in accordance with the methodology, may related to forces generally exerted on the frame 72.

[0108] Again, the frame 72 is manufactured from a composite material and typically, a composite polymeric material as discussed above. Typically, the frame 72 may be integrally formed, and may comprise a lattice structure. However, in some cases, the frame may comprise integrally formed modules which may be interconnected to form the frame 72. These modules may be relatively easily replaced when damaged or worn.

[0109] Typically, the frame 72 or modules as the case may be, may be formed by means of a moulding process. Members of the frame 72 may be hollow-cored. The hollow cores of the frame members may be manufactured by providing foam inserts within the moulds during the manufacturing process.

[0110] It is believed that the use of composite materials and interchangeable or modular components in the manufacturing of the carrier 10 and heavy-duty vehicle 70 may have various benefits.

[0111] Firstly, the use of composite materials is associated with a reduced weight of construction. This may therefore play a significant part in reducing overall energy expenditure associated with the use of the vehicle.

[0112] Furthermore, these materials may provide higher degrees of stiffness and durability, improved ability to withstand fatigue, shocks and vibrations, while worn or damaged parts may be easier to replace.

[0113] It will be appreciated that the above description only provides an example embodiment of the invention and that there may be many variations without departing from the spirit and / or the scope of the invention. It is easily understood from the present application that the particular features of the present invention, as generally described and illustrated in the figures, can be arranged and designed according to a wide variety of different configurations. In this way, the description of the present invention and the related figures are not provided to limit the scope of the invention but simply represent selected embodiments.

[0114] The skilled person will understand that the technical characteristics of a given embodiment can in fact be combined with characteristics of another embodiment, unless otherwise expressed or it is evident that these characteristics are incompatible. Also, the technical characteristics described in a given embodiment can be isolated from the other characteristics of this embodiment unless otherwise expressed.

Claims

CLAIMS1 ) A payload carrier, comprising: a support subassembly; and an integrated tray arrangement, wherein the support subassembly is fixed to and / or extends from the integrated tray arrangement and wherein the integrated tray arrangement forms part of a structural chassis of the payload carrier.2) The payload carrier according to claim 1 , wherein the integrated tray arrangement comprises a tray and a support structure.3) The payload carrier according to claim 2, wherein the tray operatively interacts with the support structure to facilitate transfer of loads between the support structure and the tray.4) The payload carrier according to claim 2, wherein the support structure is situated towards an outside of the tray; wherein the support structure is manufactured from one of a polymeric composite material and a metal including steel, stainless steel and aluminium; and wherein the support structure is designed and / or shaped in accordance with an analysis-led design approach.5) The payload carrier according to claim 2, wherein the support structure is one of: i) an exoskeleton forming a cradle within which the tray is received; and ii) integrally formed with the tray.6) The payload carrier according to claim 2, wherein the support structure comprises at least a first peripherally extending member.7) The payload carrier according to claim 6, wherein the peripherally member is located peripherally about an open top portion of the tray.8) The payload carrier according to claim 2, wherein the support structure includes longitudinal ribs extending at least partially underneath the tray and supporting the tray from below.9) The payload carrier according to claim 8, in which the support structure includes at least two central longitudinal ribs and two outer longitudinal ribs.10) The payload carrier according to claim 2, wherein the longitudinal ribs extend between opposing portions of a peripherally extending member and wherein the longitudinal ribs are fixed to or integrally formed with the peripherally extending member.1 1 ) The payload carrier according to claim 2, wherein a periphery of an open-ended top of the tray is reinforced by a rim arrangement, comprising one of a single rim and a plurality of interlocking rim sections.12) The payload carrier according to claim 2, wherein the support structure comprises a plurality of cross-extending members and interconnecting members.13) The payload carrier according to claim 2, wherein the support structure further comprises a first and second subframe extending relative to the tray in a forward and rearward direction, respectively.14) The payload carrier according to claim 2, wherein the support structure further comprises forward-extending and rearward-extending shear panels.15) The payload carrier according to claim 14, wherein the shear panels extend in a plane substantially parallel to a surface on which the payload carrier is operatively supported.16) The payload carrier according to claim 14, wherein the shear panels are substantially trapezoidal viewed from the top.17) The payload carrier according to claim 14, wherein the shear panels have a thickness in the range of 2mm to 6mm.18) The payload carrier according to claim 17, wherein the shear panels have a thickness of about 4mm.19) The payload carrier according to claim 14, wherein the shear panels are manufactured from one of a metal and composite material.20) The payload carrier according to claim 14, wherein the shear panels are fixed directly or indirectly to the tray.21 ) The payload carrier according to claim 2, further comprising at least a first external anchoring arrangement extending beyond an outer surface of the tray.22) The payload carrier according to claim 21 , wherein the external anchoring arrangement comprises an external plate and a backplate, wherein a portion of the external anchoring arrangement extends at least partially through the tray and between the external plate and backplate, to sandwich the tray between the external plate and backplate wherein the external plate and / or backplate are bonded to the tray and wherein the external anchoring arrangement is manufactured from a metal selected from the list comprising steel and stainless steel.23) The payload carrier according to claim 21 , wherein the external anchoring arrangement is fixed relative to the support structure.24) The payload carrier according to claim 1 , wherein the support subassembly comprises a drivetrain or undercarriage subassembly including one of a set of wheels and a set of tracks.25) The payload carrier according to claim 24, configured as a haul vehicle and wherein at least some of the wheels or tracks are driven.26) The payload carrier according to claim 2, wherein the tray has a shape which is one of U- shaped in cross-section and substantially hemispherical.27) The payload carrier according to claim 26, wherein the tray defines a trough portion and sidewall portions, and wherein a wall thickness of the trough portion exceeds a wall thickness of the sidewall portions, thereby to increase bending stiffness, torsional stiffness and impact strength of the trough portion.28) The payload carrier according to claim 27, wherein the wall thickness of the sidewall portions is in the range of 4mm to 12mm.29) The payload carrier according to claim 28, wherein the wall thickness of the sidewall portions is about 8mm.30) The payload carrier according to claim 27, wherein the wall thickness of the trough portion is in the range of 8mm to 20mm.31 ) The payload carrier according to claim 30, wherein the wall thickness of the trough portion is about 12mm.32) The payload carrier according to claim 2, wherein the tray is manufactured from a material selected from the list comprising: metals, including steel and stainless steel; composite materials; and a layered material, comprising at least one metal layer and one composite layer.33) The payload carrier according to claim 2, wherein the tray comprises a plurality of tray layers, at least one of which manufactured from a composite material and wherein the tray is designed or shaped in accordance with an analysis-led design approach.34) The payload carrier according to claim 33, wherein the tray layers include: a main tray layer; and a liner layer received over the main tray layer.35) The payload carrier according to claim 34, wherein the main tray layer comprises one of a steel layer and a polymeric layer, and wherein the liner layer comprises one of: i) a singlepiece moulded layer; ii) a layer sprayed onto the main tray layer; iii) a layer cast onto the main tray layer; and iv) a layer made up of adjoining bolted sections, and wherein the liner layer comprises one of a steel layer and a polymeric layer, and wherein the polymeric layer comprises a fibre-reinforced polymeric layer, the fibre of the fibre-reinforced polymeric layer comprising one of a glass-fibre, carbon fibre and natural fibre.36) The payload carrier according to claim 34, wherein an operatively bottom portion of the main tray layer comprises a locally thickened wall portion and wherein a strike plate is optionally sandwiched between operatively bottom portions of the tray layer and the liner layer.37) The payload carrier according to claim 2, wherein an outer surface of the tray is lined with individual protective armour panels manufactured from a material selected from the list comprising metal including steel and stainless steel, and composite materials.38) The payload carrier according to claim 1 , wherein the integrated tray arrangement has an open-ended top configured to receive the payload therethrough and wherein the payload takes the form of raw material.39) The payload carrier according to claim 1 , wherein the integrated tray arrangement includes a measuring sensor to measure at least one of stress, strain, acceleration, temperature, and vibration and wherein the measuring sensor comprises one of a strain gauge, accelerometer and thermocouple.40) The payload carrier according to claim 1 , wherein the integrated tray arrangement has a roof portion and a closable opening configured as a door.41 ) A heavy-duty vehicle, comprising a frame manufactured from a composite material and shaped and designed based on an analysis-led design approach.42) The heavy-duty vehicle according to claim 41 , wherein the frame is manufactured from a polymeric material in the form of a fibre-reinforced polymeric material and wherein the fibre comprises one of a glass-fibre, carbon fibre and natural fibre.43) The heavy-duty vehicle according to claim 41 , wherein the frame comprises an integrally formed lattice structure.44) The heavy-duty vehicle according to claim 41 , wherein the frame is formed through or by means of a moulding process.45) The heavy-duty vehicle according to claim 44, wherein the frame comprises hollow frame members formed by foam inserts provided in a mould used during the moulding process.46) The heavy-duty vehicle according to claim 41 , wherein the frame includes a measuring sensor to measure at least one of stress, strain, acceleration, temperature, and vibration exerted on or experienced by frame and wherein the measuring sensor comprises one of a strain gauge, accelerometer and thermocouple.

Images