Ballast trough for batteries, production method, and mobile working machine

Abstract

The invention relates to a ballast trough (40) intended for receiving drive components (36) for a mobile working machine (10), in particular for an industrial truck (12). The ballast trough (40) comprises: at least one inner chamber (46) for receiving at least one drive component (36), in particular a drive battery (38) or a fuel cell; a sleeve (42) having an outer wall (48); and a solidified, weight-increasing ballast filling (80) made of composite material. The ballast filling (80) comprises a metal granulate (84) and a casting material (86) surrounding the metal granulate (84). The invention also relates to a method intended for producing a ballast trough (40) having a ballast filling (80).

Description

Ballasttroq ​​for batteries, manufacturing processes and mobile work machines

[0001] The present disclosure relates to a ballast trough for accommodating drive batteries for a mobile work machine, comprising at least one internal chamber for accommodating at least one drive battery. Furthermore, the present disclosure relates to a method for producing a ballast trough and to a mobile work machine having such a ballast trough.

[0002] DE 102013 114 944 A1 discloses a mobile work machine in the form of an industrial truck designed as a so-called counterbalance forklift. DE 102013 114 944 A1 proposes upgrading such a counterbalance forklift for the use of lightweight, high-performance batteries by installing a counterweight that compensates for the weight reduction when replacing conventional lead-acid batteries. Furthermore, it is proposed to position counterweights as favorably as possible so that, with an overall reduction in weight, a sufficiently large counter-torque can be generated with respect to a load moment on a front axle of the forklift. EP 2 887420 A1 and EP 2 990247 A1 pursue similar approaches.

[0003] Mobile work machines include, for example, industrial trucks, which include forklifts. Forklifts can be powered by internal combustion engines or electric motors. Electric-powered forklifts equipped with lead-acid batteries are known in the art. Forklifts typically have a lifting unit with a fork for reaching under and lifting a load. If the load is very large and / or positioned very far in front of the forklift's chassis, the risk of the forklift tipping increases. Therefore, the drive batteries of such forklifts are positioned specifically to compensate for any load moments caused by the load being lifted and transported using their considerable dead weight. Similar considerations apply to wheel loaders, excavators, and other mobile work machines.

[0004] Due to advances in battery technology, mobile machines can in principle also be equipped with drive batteries with higher energy density (energy per unit of weight). For example, the potential energy density of lithium-ion batteries is several times that of lead-acid batteries. The drive batteries can be permanently integrated into the mobile machine or designed to be easily removable / replaceable. With easy-to-replace design, a discharged drive battery can be swapped for a charged one, quickly making the mobile machine usable again. If the drive battery is integrated into the mobile machine, it is charged within the machine.

[0005] In addition to the undeniable advantages of using modern batteries (cycle stability, charging speed, ease of maintenance), it must also be taken into account that the high weight of lead-acid batteries cannot often be achieved, which often increases the tendency of the mobile work machine to tip over due to the lack of sufficiently high counterweights.

[0006] One approach is to make battery boxes heavier to compensate for the lower weight of the lighter batteries. However, it has been shown that resource consumption is very high, especially when using massive steel structures. The use of mineral materials (building materials) such as Concrete is conceivable, but it cannot achieve the high density (weight per unit volume) of steel structures.

[0007] Similar considerations apply to the integration of fuel cells and other energy storage / supply systems for mobile work machines. Such applications may also require additional ballast to ensure the desired properties (tip stability, load-bearing capacity of lifting devices or other work equipment, center of gravity, and the like).

[0008] Against this background, the present disclosure is based on the object of providing a ballast trough for accommodating drive batteries for a mobile work machine, in particular for an industrial truck, which has a high density and thus offers good weight compensation capabilities. Furthermore, the ballast trough should be manufactured as cost-effectively as possible. Finally, the ballast trough should be manufactured with the lowest possible material consumption. The ballast trough should have sufficient mechanical stability, particularly with regard to impact resistance.

[0009] According to a first aspect, the present disclosure relates to a ballast trough for accommodating drive batteries for a mobile work machine, in particular for an industrial truck, having at least one inner chamber for accommodating at least one drive battery, a shell with an outer wall, and having a solidified, weight-increasing ballast filling made of composite material, which comprises a metal granulate and a potting material surrounding the metal granulate.

[0010] In this way, a sufficiently heavy ballast trough can be provided with little effort and, in particular, with little primary raw material consumption, which ensures the necessary stability when using the mobile work machine.

[0011] For example, the composite material comprises 70-90% by weight of metal granulate and 30-10% by weight of potting material, which in particular add up to 100% by weight, but at least to 95% by weight. This does not exclude the possibility of small air pockets and / or inclusions of other materials. When using scrap, for example, this may include paint residues, rust particles, dirt particles, and the like.

[0012] In exemplary embodiments, the material of the ballast trough has a density of up to at least 60% of the density of pure (compact) steel (approx. 7.85 g / cm 3). In exemplary embodiments, the density is at least 65% of the density of pure steel. In exemplary embodiments, the density is at least 70% of the density of pure steel. In exemplary embodiments, the density is at least 80% of the density of pure steel. In exemplary embodiments, the density is at least 90% of the density of pure steel.

[0013] In exemplary embodiments, the ballast trough serves to accommodate a drive battery with increased energy density, with any reduced weight of the drive battery being compensated for by the ballast trough. In this way, the drive battery, together with the weight-increasing ballast trough, can contribute to increased stability and tipping resistance. The drive battery and the ballast trough can be collectively referred to as a battery module.

[0014] The metal granulate is a small-sized material obtained, for example, through recycling. The necessary stability is imparted to the material by the casting process. Together, the metal granulate and the casting material form at least one composite body, which can serve as ballast filling.

[0015] The outer wall is made primarily of sheet metal, usually steel sheets. The shell with the outer wall can be produced from relatively thin sheet material with minimal use of primary raw materials, compared to ballast troughs, where the ballast weight is generated by comparatively thick steel plates. Possible processing steps for processing the sheet material to produce the shell include, for example, forming, bending, separating / cutting, and, if necessary, joining processes such as welding, clinching, riveting, screwing, and the like. Comparatively thin steel sheets are easier to process than heavy steel plates. This contributes to reducing the overall effort required to produce the ballast trough.

[0016] Nevertheless, the ballast trough obtained in this way is sufficiently mechanically stable. In particular, the impact resistance regularly required for forklift use can be met by combining the shell (usually made of steel sheets) with the ballast filling (with a comparatively high steel content embedded in a grout). The metal granules are (largely) embedded in the grout. The grout forms a matrix for the metal granules. The ballast filling stiffens the shell and increases its weight.

[0017] Furthermore, the ballast trough has sufficiently high inherent stability, allowing easy handling of the ballast trough with or without the drive battery accommodated therein. The ballast trough, with the drive battery accommodated therein, can be adapted to the weight and external dimensions of traditional lead-acid batteries. This allows for easy replacement with modern high-performance batteries (e.g., lithium-ion batteries or the like). The present disclosure is expressly not limited to drive batteries with lithium-ion accumulators.

[0018] According to an exemplary embodiment, the metal granulate is formed from small-sized ferrous metal waste. In particular, the metal granulate is formed from punching waste, metal chips, and / or crushed metal scrap.

[0019] For example, so-called punching slugs can be used as metal granulate. In general, waste from separating or removing processes (cutting, punching, machining, grinding) can be used as metal granulate. Nibbling, for example, produces small punching slugs with a relatively uniform shape. Turning, drilling, and / or milling produce chips that can be broken up as needed to reduce or standardize grain sizes.

[0020] It is also conceivable, in principle, to mechanically or otherwise crush metal scrap that is otherwise unusable to form the metal granulate. It is also conceivable for the metal granulate to consist of different raw materials (e.g., a mixture of crushed scrap, punching slugs, and metal shavings). Given their comparatively high density (weight per unit volume) and availability, ferrous metal waste, including steel waste, is particularly suitable.

[0021] In the context of the present disclosure, the term "metal granules" refers to sufficiently small metal bodies, the shape of which, however, need not be specified within narrow limits. In particular, it is not necessary for the metal granules to be spherical, disc-shaped, or similarly homogeneous. Nevertheless, it may be advantageous if the metal particles do not exceed a certain grain size. For illustrative purposes only, reference is made to semolina, match heads, peas, and hazelnuts as examples of different grain sizes. This is not to be understood as a limitation.

[0022] According to another exemplary embodiment, the metal granulate is a free-flowing bulk material formed from mechanically crushed metal waste or steel grit. If the metal granulate is free-flowing, filling the casting mold with the metal granulate for subsequent casting with the casting material is easy. The casting mold can be provided by the shell of the ballast trough itself. The casting mold can also be separate from the shell of the ballast trough.

[0023] Steel shot, for example, is used as a blasting agent for surface finishing. It is, for example, crushed material based on molten gray cast iron. Steel shot or waste materials containing steel shot can be (exclusively or partially) a component of the free-flowing bulk material.

[0024] In exemplary embodiments, the casting mold is first filled with the free-flowing metal granulate and then with the casting material. In exemplary embodiments, the filling with the metal granulate and the Casting material, at least temporarily, in parallel. In exemplary embodiments, the metal granulate and the casting material are mixed before filling the casting mold and poured into the casting mold as a mixture.

[0025] According to another exemplary embodiment, the potting material is formed from a synthetic resin, in particular a casting resin. This allows the metal granulate to be sufficiently solidified and enclosed. Once the synthetic resin has cured, the ballast filling forms a solid body.

[0026] The casting resin can be, for example, polyester resin, polyurethane resin (polyurethane), epoxy resin, silicone resin, vinyl ester resin, phenolic resin, acrylic resin (PMMA), and the like. The casting resin may optionally be provided with additives, fillers, and the like. The casting resin can be a one-component (1K) casting resin or a two-component (2K) casting resin. Of course, a casting resin with more than two components is also conceivable. The casting resin can flow into the mold in an at least partially liquid state and, if necessary, penetrate and enclose the metal granules.

[0027] According to another exemplary embodiment, the shell further comprises an inner wall offset inward relative to the outer wall, which surrounds the inner chamber, with the ballast filling arranged between the outer wall and the inner wall. In this way, neither the propulsion battery accommodated in the inner chamber nor the environment outside the ballast trough comes into direct (mechanical) contact with the ballast filling. For example, the shell of the ballast trough is formed by an inner shell and an outer shell, between which space is provided for the ballast filling.

[0028] The ballast filling can stiffen the hull and ensure a strong connection between the inner shell and the outer shell.

[0029] The shell, which has an outer and inner wall, can be constructed entirely using appropriate sheet metal constructions. Joining processes can include welding, clinching, flanging, bonding, screwing, and similar methods. For example, the shell consists of steel sheets, which may be formed, with joints created by welding.

[0030] According to another exemplary embodiment, the outer wall and the inner wall form at least one fillable hollow chamber of the shell. This allows the ballast filling (metal granules and potting material) to be poured directly into the hollow chamber, so that the shell itself provides the casting mold.

[0031] According to another exemplary embodiment, the ballast trough further comprises a closure piece that connects the outer wall and the inner wall adjacent to a receiving opening of the ballast trough. If the inner wall and the outer wall are each formed by a shell, a circumferential open edge is created between an upper edge of the inner wall and an upper edge of the outer wall when the inner wall is inserted into the outer wall. This area can be at least partially closed off by the closure piece. Nevertheless, a receiving opening may still be available in the inner chamber, for example, to accommodate the drive battery.

[0032] According to another exemplary embodiment, the end piece has at least one filling opening for introducing the ballast filling. According to another exemplary embodiment, the at least one filling opening is hermetically sealable. The end piece can connect the upper ends of the inner wall and the outer wall sufficiently tightly to improve the overall stability of the shell. The metal granulate and / or the potting material can be poured through the at least one filling opening to fill the ballast filling.

[0033] After filling (and curing) the ballast filling, at least one filling opening can be sealed sufficiently tightly (if necessary hermetically), for example by a closure flap, which can be tightly secured by welding if necessary. In this way, any outgassing of the ballast filling (the casting material) can be reduced or even prevented. This does not exclude that, if necessary, measures are provided to release excess pressure.

[0034] According to another exemplary embodiment, the ballast filling is completely enclosed in the ready-to-use state of the ballast trough and, in particular, sealed in a dust-tight and / or gas-tight manner. According to another exemplary embodiment, the ballast filling is completely surrounded by the sheet metal material in the ready-to-use state of the ballast trough. When the ballast filling is completely enclosed, there is no or only a reduced adverse interaction (outgassing or the like) of the ballast filling with the environment.

[0035] According to another exemplary embodiment, the inner wall and the outer wall are formed from sheet metal, in particular from metal sheets. According to another exemplary embodiment, at least one wall and / or one floor of the ballast trough is designed in a sandwich-like manner. "Sandwich-like" in this context means that the ballast filling is arranged between two layers of sheet metal (one for the inner wall and one for the outer wall).

[0036] According to a further aspect, the present disclosure relates to a mobile work machine, in particular an industrial truck, comprising a chassis, an at least partially electric motor drive, and a drive battery arranged in a ballast trough according to one of the preceding claims. The drive battery and the ballast trough can be collectively referred to as a battery module.

[0037] In this way, the drive battery can be conveniently positioned with the ballast trough in the work machine. This provides, for example, weight compensation / torque compensation for a working device of the mobile work machine. The working device can be, for example, a lifting device, an integrated device, or an attachment. For example, the industrial truck is a forklift with a lifting device with vertically movable forks for lifting, carrying, and lowering loads.

[0038] In an exemplary embodiment, the assembly comprising the drive battery and the ballast trough is adapted in terms of external dimensions and weight to the external dimensions and weight of conventional lead-acid batteries for use in forklift trucks or similar industrial trucks.

[0039] According to a further aspect, the present disclosure relates to a method for producing a ballast trough according to at least one of the embodiments described herein, comprising the following steps: Provision of a casting mold, Provision of filling materials, comprising provision of a metal granulate and provision of a potting material, Production of the filling, comprising parallel or staggered filling of the casting mold with the metal granulate and the casting material, and Curing the potting material, wherein the composite material produced in this way comprises 70-90% by weight of metal granulate and 30-10% by weight of potting material, which in particular complement each other to at least 95% by weight.

[0040] In this way, the comparatively small metal granules can be solidified and bound by the casting material, creating a solid body that can form the ballast filling.

[0041] According to an exemplary embodiment of the method, the shell of the ballast trough is used as a casting mold. In this way, the shell itself serves as the casting mold. This is particularly suitable for a double-walled shell with an inner and an outer wall. The space (hollow chamber) between the inner and outer walls can be filled with metal granules and the casting material. The ballast filling created in this way further reinforces and stiffens the shell of the ballast trough.

[0042] According to a further exemplary embodiment of the method, filling the casting mold comprises filling the casting mold through at least one filling opening. According to a further exemplary embodiment of the method, the at least one filling opening is closed after the filling process to seal the ballast filling. This can, for example, include closing the hollow chamber to seal the ballast filling. The at least one filling opening does not always have to be closed.

[0043] According to a further exemplary embodiment of the method, the casting mold is a different casting mold from the shell of the ballast trough, in particular a casting mold in the form of a permanent mold or a lost mold. In this way, the ballast filling (in one or more parts) can also be produced by casting. During production in an external casting mold, the ballast trough is formed by inserting the (already solidified) ballast filling (in one or more parts) into the shell. In this way, the shell is sufficiently weighted to serve as a ballast trough and counterweight.

[0044] According to another exemplary embodiment, the method further comprises introducing the hardened ballast filling into the shell of the ballast trough, in particular into a hollow chamber between an inner wall and an outer wall. According to another exemplary embodiment, the method further comprises closing the hollow chamber to seal the ballast filling.

[0045] It is understood that the features mentioned above and those to be explained below can be used not only in the combination specified in each case, but also in other combinations or on their own, without departing from the scope of the present disclosure.

[0046] Further features and advantages of the invention will become apparent from the following description and explanation of several exemplary embodiments with reference to the drawings. They show: Fig. 1: a schematic side view of a mobile work machine in the form of a forklift truck; Fig. 2: a perspective view of a ballast trough for accommodating a traction battery; Fig. 3: a sectional view through the shell of the ballast trough in Fig. 2 along the line III-III therein; Fig. 4: another view of the ballast trough according to Fig. 3 in a state filled with the ballast filling; Fig. 5: different views of a casting mold to illustrate a process sequence for filling the casting mold; and Fig. 6: a block diagram illustrating an embodiment of a method for producing a ballast trough.

[0047] Fig. 1 illustrates a side view of a mobile work machine, designated overall by 10. By way of example, the mobile work machine 10 is designed as an industrial truck 12, in particular as a forklift 14. The forklift 14 is, for example, a so-called counterbalance forklift. It is understood that principles and configurations of ballast troughs according to the present disclosure can also be used in work machines 10 / industrial trucks 12 other than forklifts 14. For illustrative purposes, the following explanation will primarily refer to the forklift 14.

[0048] The mobile work machine 10 can also be a tractor, for example, for a tugger train or the like, a tractor, a loader, and / or a mobile construction machine. Areas of application can include material flow (for example, intralogistics), agriculture and forestry, construction, and similar industries. Areas of application are typically those where a favorable center of gravity and high tipping stability of the work machines involved are important.

[0049] The forklift 14 comprises, in a generally known manner, a chassis 20, a frame 22, and a body 24. The forklift 14 is designed to lift, lower, and transport a load 26, which can be grasped, for example, with a fork 28 and moved vertically by a working device 30, designed here as a lifting device.

[0050] A further component of the mobile work machine 10, designed here as a forklift truck 14, is a drive component 36, which can be used, for example, to supply energy to a travel drive 34, but also for other purposes.

[0051] The forklift 14 has a drive system 34 (only schematically indicated in Fig. 1) and—as drive component 36—a drive battery 38 for supplying power to the drive system 34. It is understood that the drive battery 38 can also directly or indirectly supply power to the work device 30. The drive system 34 comprises, for example, at least one electric motor for driving a driven axle of the forklift 14.

[0052] The drive component 36 is usually a drive battery 38. However, it can also be a fuel cell or another component for providing energy for the drive system 34 or other components of the mobile work machine 10.

[0053] In the forklift 14, the drive battery 38 is a key component for weight compensation when the load 26 is raised. Conventional drive batteries, for example, are designed as lead-acid batteries with a comparatively low energy density (energy per unit of weight), so that, with a defined battery capacity, the drive battery's own weight already contributes sufficiently to weight compensation.

[0054] If a high-performance battery or a battery that is lightweight for other reasons is installed with the drive battery 38, the weight of the (heavy) lead-acid batteries cannot be compensated, so Particularly with heavy loads 26, there may even be a risk of the forklift truck 14 tipping over. To ensure adequate weight compensation, the drive battery 38 is arranged in a ballast trough 40. For example, such a module comprising the ballast trough 40 and the drive battery 38 arranged therein is arranged (possibly significantly) behind the front axle of the chassis 20 and close to the ground. In this way, moments about the front axle generated by the load 26 can be compensated by a corresponding counterweight, which is (to a considerable extent) due to the drive battery 38 and the ballast trough 40.

[0055] Fig. 2 shows a perspective view of a ballast trough 40 for accommodating (at least) one drive component, for example, a drive component in the form of a drive battery 38. The ballast trough 40 has a shell 42, typically made of sheet steel. The shell 42 encloses an inner chamber 46, which serves to accommodate one or more drive batteries 38. The shell 42 is designed, for example, as a sheet metal construction.

[0056] The shell comprises an outer wall 48 and an inner wall 50 offset from the outer wall 48 toward the inner chamber 46. The inner wall 50 defines the inner chamber 46. At least one fillable hollow chamber 52 is formed between the outer wall 48 and the inner wall 50.

[0057] The inner wall 50 forms an inner shell. The outer wall 48 forms an outer shell. The casing 42 further comprises an end piece 58 that connects the outer wall 48 and the inner wall 50 to one another at their respective upper edges. In the exemplary embodiment, the end piece 58 has one or more filling openings 60 through which the at least one hollow chamber 52 is accessible. In this way, the at least one hollow chamber 52 can be filled with material. The end piece 58 is, for example, welded to the outer wall 48 and the inner wall 50.

[0058] In exemplary embodiments, the shell 42 is made of comparatively thin-walled sheet steel. The shell 42 alone does not heavy enough to ensure adequate weight compensation together with the drive battery 38.

[0059] Fig. 3 shows a section through the shell 42 along the line III-III in Fig. 2. The view orientations are the same in Fig. 3 and Fig. 4. Fig. 3 shows the shell 42 of the ballast trough 40 in an unfilled state. Fig. 4 shows the shell 42 and thus the ballast trough 40 in a filled state.

[0060] The cross-sectional view shown in Fig. 3 shows that, for example, the outer wall 48 and the inner wall 50 are formed from appropriately processed sheet steel. The inner wall 50 is offset from the outer wall 48 toward the inner chamber 46. The casing 42 is a double-walled casing. The end piece 58 is designed, for example, as a cover for the at least one hollow chamber 52. The end piece 58 exposes a receiving opening 70 through which the drive batteries 38 can be inserted into the inner chamber 48.

[0061] The at least one hollow chamber 52 can be filled via one or more filling openings 60. Fig. 4 additionally illustrates that the filling openings 60 can be closed by closures 62 when the ballast trough 40 is filled. This can, for example, create a hermetic seal.

[0062] In the state shown in Fig. 4, a ballast filling 80 is introduced into the at least one hollow chamber 52, which overall ensures a significant increase in the weight of the ballast trough 40. Preferably, the resulting density (weight per unit volume) is more than 50% of the density of steel; more preferably, the resulting density of the ballast filling 80 is more than 60% of the density of steel. Further preferably, the resulting density of the ballast filling 80 is more than 70% of the density of steel. In this way, the ballast trough 40 is sufficiently heavy and mechanically stable for use in the forklift 14 and / or other mobile work machine 10.

[0063] Fig. 4 further shows that the ballast trough 40 is at least partially sandwich-shaped. The ballast filling 80 sits between the outer wall 48 and the inner wall 50. This results in favorable material properties. This relates, on the one hand, to the desired high weight. Furthermore, high mechanical stability is achieved by combining comparatively thin metal sheets with the ballast filling. 80

[0064] Fig. 5 illustrates, using several schematic representations A-D, a conceivable sequence for producing the ballast filling 80. The ballast filling 80 is produced in a casting mold 82. In exemplary embodiments, the casting mold 82 corresponds to the shell 42, in whose at least one hollow chamber 52 the ballast filling 80 is produced. In further exemplary embodiments, the casting mold 82 is a separate casting mold from the shell 42. Therefore, if the casting mold 82 is not the shell 42 itself, the ballast filling 80 must be inserted into the shell 42 after casting.

[0065] Fig. 5 illustrates in partial view A that, in the exemplary embodiment shown, a metal granulate 84 is first introduced into the casting mold 82. In particular, this is a free-flowing, comparatively small-particle metal granulate 84. Preferably, recycled material from steel materials is used as the metal granulate 84. For example, the use of punching slugs, chips, shredded metal scrap and the like is suitable. The metal granulate 84 can comprise mechanically crushed steel material. The metal granulate 84 can be provided cost-effectively. No or only a small amount of primary raw materials is required. Metal waste can be recycled / upcycled without the need for complex processing processes.

[0066] Partial view B shows that a desired fill level with the metal granulate 84 has been reached. A (liquid or viscous) potting material 86 can then be introduced into the mold 82, this is shown in partial view C. The potting material 86 fills the cavities between the particles of the metal granulate 84. The potting material 86 flows around the metal granulate 84 and embeds it in a matrix. In partial view D, the desired fill level for the potting material 86 has been reached, so that after the Curing of the casting material 84 provides the ballast filling 80 with the desired properties.

[0067] The process illustrated in Fig. 5 can involve directly filling the shell 42 of the ballast trough 40; compare again Fig. 3 (unfilled) and Fig. 4 (ballast filling 80 in at least one hollow chamber 52). If the shell 42 itself provides the casting mold 82, the cost of manufacturing the ballast trough 40 can be further reduced.

[0068] Fig. 6 illustrates an exemplary embodiment of a method for producing a ballast trough using a schematic flowchart. In the exemplary embodiment, the method begins at step S10.

[0069] Step S12 relates to the provision of a casting mold. This may, in particular, involve the creation of a shell with at least one fillable hollow chamber, wherein the shell is also a component of the ballast trough to be produced. In this way, the shell can serve directly as a casting mold and be filled.

[0070] Subsequent steps S14 and S16 relate to the provision of a metal granulate (step S14) and the provision of a potting material (step S16). The metal granulate and the potting material can initially be provided separately. However, it is also conceivable to provide a mixture of the metal granulate and the potting material.

[0071] The casting mold is filled in step S18. This can involve sequential (one after the other, staggered) filling, whereby the casting mold is first filled with the metal granules and then with the potting material. The metal granules are, for example, in at least a free-flowing state. The potting material is, for example, in a liquid or at least viscous state.

[0072] However, the filling in step S18 can also be carried out simultaneously, at least temporarily, for the metal granules and the potting material. This can, for example, involve filling with a pre-prepared mixture of metal granules and potting material.

[0073] A subsequent step S20 involves curing the potting material. This creates a solidified ballast filling in which the metal granules are embedded in the cured potting material.

[0074] In the exemplary embodiment, the method ends at step S22.

Claims

Patent claims 1. Ballast trough (40) for receiving drive components (36) for a mobile work machine (10), in particular for an industrial truck (12), with at least one inner chamber (46) for receiving at least one drive component (36), in particular a drive battery (38) or a fuel cell, a shell (42) with an outer wall (48), and with a solidified, weight-increasing cast ballast filling (80) made of composite material, which comprises a metal granulate (84) and a casting material (86) surrounding the metal granulate (84).

2. Ballast trough (40) according to claim 1, wherein the metal granulate (84) is formed from small-sized ferrous metal waste, in particular from punching waste, metal chips and / or crushed metal scrap.

3. Ballast trough (40) according to claim 1 or 2, wherein the metal granulate (84) is a free-flowing bulk material formed from mechanically crushed metal waste or steel grit.

4. Ballast trough (40) according to one of claims 1 - 3, wherein the casting material (86) is formed from a synthetic resin, in particular from a casting resin.

5. Ballast trough (40) according to one of claims 1-4, wherein the shell (42) further comprises an inner wall (50) which is offset inwardly relative to the outer wall (48) and surrounds the inner chamber (46), and wherein the ballast filling (80) is arranged between the outer wall (48) and the inner wall (50).

6. Ballast trough (40) according to claim 5, wherein the outer wall (48) and the inner wall (50) form at least one fillable hollow chamber (52) of the shell (42).

7. Ballast trough (40) according to claim 6, further comprising an end piece (58) connecting the outer wall (48) and the inner wall (50) adjacent to a receiving opening (70) of the ballast trough (40).

8. Ballast trough (40) according to claim 7, wherein the end piece (58) has at least one filling opening (60) for introducing the ballast filling (80), and in particular wherein the at least one filling opening (60) is hermetically sealable.

9. Ballast trough (40) according to one of claims 1-8, wherein the inner wall (50) and the outer wall (48) are formed from sheets, in particular from metal sheets, and wherein at least one wall and / or a bottom of the ballast trough (40) are designed in a sandwich-like manner.

10. Mobile work machine (10), in particular industrial truck (12), with a chassis (20), with an at least partially electric motor drive (34) and with a drive component (36), in particular a drive battery (38) or a fuel cell, which is arranged in a ballast trough (40) according to one of the preceding claims.

11. A method for producing a ballast trough (40) according to one of claims 1 - 10, with the following steps: Providing a casting mold (82), Providing filling materials, comprising providing a metal granulate (84) and providing a potting material (86), Production of the ballast filling (80), comprising parallel or staggered filling of the casting mold (82) with the metal granulate (84) and the casting material (86), and Curing the potting material (86), wherein the composite material produced in this way comprises 70-90% by weight of metal granulate (84) and 30-10% by weight of potting material, which in particular complement each other to at least 95% by weight.

12. The method according to claim 11, wherein the shell (42) of the ballast trough (40) is used as a casting mold (82).

13. The method according to claim 1, wherein the filling of the casting mold (82) comprises filling the casting mold (82) through at least one filling opening, in particular wherein the at least one filling opening can be closed after the filling process in order to seal the ballast filling (80).

14. The method according to claim 11, wherein the casting mold (82) is a casting mold (82) different from the shell (42) of the ballast trough (40), in particular a casting mold (82) in the form of a permanent mold or a lost mold.

15. The method according to claim 14, further comprising introducing the hardened ballast filling (80) into the shell (42) of the ballast trough (40), in particular into a hollow chamber (52) between an inner wall (50) and an outer wall (48), and in particular closing the hollow chamber (52) to seal the ballast filling (80).

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