Mobile machine interchangeable alternative energy module system

Abstract

A method of operating a mobile machine, including connecting a first power module to the mobile machine, the first power module including a first energy source type, removing the first power module from the mobile machine, and connecting a second power module to the mobile machine, the second power module including a second energy source type, different than the first energy source type.

Description

MOBILE MACHINE INTERCHANGEABLE ALTERNATIVE ENERGY MODULE SYSTEMCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit under Articles 4 and 8 of the Stockholm Act of the Paris Convention for the Protection of Industrial Property of U.S. Provisional Patent Application No. 63 / 651,664, filed on May 24, 2024, which application is incorporated herein by reference in its entirety.TECHNICAL FIELD

[0002] The present disclosed subject matter relates generally to the field of mobile machines, and more particularly to an improved mobile machine modular electric power system.BACKGROUND ART

[0003] Movable machinery or heavy equipment or heavy machinery or earthmover refers to heavy-duty vehicles specially designed to execute construction tasks, most frequently involving earthwork operations or other large construction tasks. Some examples of movable machinery are bulldozers, agricultural tractors, excavators, cranes, backhoes, skid steers, and loaders. Movable machinery usually comprises five equipment systems: the implement, traction, structure, power train, and control / information. Movable machinery functions through the mechanical advantage of a simple machine, the ratio between input force applied and force exerted is multiplied, making tasks which could take hundreds of people and weeks of labor without heavy equipment far less intensive in nature. Some equipment uses hydraulic drives as a primary source of motion. Internal combustion engines, namely diesel engines, are the dominant power source of movable machinery.BRIEF SUMMARY

[0004] In view of the foregoing, it is an obj ect of the present disclosure to provide a system and method for powering movable machinery with a removable modular system.

[0005] With parenthetical reference to corresponding parts, portions, or surfaces of the disclosed embodiment, merely for the purposes of illustration and not by way of limitation, the present disclosure provides a method (500) of operating a mobile machine (10), comprising connecting a first power module (100) to the mobile machine (10), the first power module (100) including a first energy source type (200, 300, 400), removing the first power module (100) from the mobile machine (10), and connecting a second power module (100) to the mobile machine(10), the second power module (100) including a second energy source type (200, 300, 400), different than the first energy source type (200, 300, 400).

[0006] In an exemplary embodiment, the step of connecting the first power module (100) to the mobile machine (10) may comprise mechanically connecting the first power module (100) to the mobile machine (10), electrically connecting the first power module (100) to the mobile machine (10), and fluidly connecting the first power module (100) to the mobile machine (10). In an exemplary embodiment, the step of mechanically connecting the first power module (100) to the mobile machine (10) may comprise arranging the first power module (100) on a base (160), and extending at least one arm (166A-166B, 170A-170B) arranged in the base (160) through a hole (110A-110B, 112A-112B) in the power module (100). In an exemplary embodiment, the step of arranging the first power module (100) on the base (160) may comprise arranging the first power module (100) on a plurality of rollers (184), the plurality of rollers (184) being rotatably connected to the base (160), and displacing the first power module (100) along the base (160) to align the at least one arm (166A-166B, 170A-170B) with the hole (110A-110B, 112A-112B).

[0007] In an exemplary embodiment, the step of electrically connecting the first power module (100) to the mobile machine (10) may comprise connecting a high voltage port (142) of the first power module (100) to a power distribution unit (60) of the mobile machine (10), connecting a low voltage port (146) of the first power module (100) to the power distribution unit (60), and connecting a communications port (146) of the first power module (100) to a controller (60) of the mobile machine (10). In an exemplary embodiment, the step of fluidly connecting the first power module (100) to the mobile machine (10) may comprise connecting a first inlet port (148A) and a first outlet port (148B) of the first power module (100) to a second inlet port (78A) and a second outlet port (78B) of the mobile machine (10), wherein the second inlet port (78A) and second outlet port (78B) are fluidly connected to a thermal module (50) for regulating the temperature of fluid. In an exemplary embodiment, one of the first energy source type (200, 300, 400) and the second energy source type (200, 300, 400) may be a battery module (200), and the other of the first energy source type (200, 300, 400) and the second energy source type (200, 300, 400) may be a combustion engine (300).

[0008] The present disclosure may provide an energy agnostic mobile machine (10), comprising a chassis (12), a traction system (16), at least one work tool (20), a thermal module (50), a motor module (40), a pump module (42), a controller (60), and a base (160) operativelyarranged for removably mounting a plurality of power modules (100), the base (160) comprising a frame (162) connected to the chassis (12), a plate (180) connected to the frame (162), and at least one arm (166A-166B, 170A-170B) displaceable with respect to the frame (162) and plate (180).

[0009] In an exemplary embodiment, the base (160) may further comprise a tube (164A- 164B) connected to the frame (162), and the at least one arm (166A-166B, 170A-170B) may be displaceable within the tube (164A-164B). In an exemplary embodiment, in an unlocked state of the base (160), the at least one arm may not extend out of an end of the tube (164A-164B), and in a locked state of the base (160), the at least one arm (166A-166B, 170A-170B) extends out of the end of the tube (164A-164B). In an exemplary embodiment, the at least one arm (166A-166B, 170A-170B) may comprise a first arm (166A-166B) arranged at a first end of the tube (164A- 164B), and a second arm (170A-170B) arranged at a second end of the tube (164A-164B). In an exemplary embodiment, the energy agnostic mobile machine (10) may further comprise a spring element (174A-174B) operatively arranged to bias the first arm (166A-166B) and the second arm (170A-170B) away from each other towards a locked state of the base (160).

[0010] In an exemplary embodiment, the base may further comprise a plurality of rollers (184) rotatably connected to the frame (162). In an exemplary embodiment, each roller (184) of the plurality of rollers (184) extends through a respective hole (182) in the plate (180). In an exemplary embodiment, the plurality of power modules (100) may comprise a first power module (100) removably connectable to the base (160), the motor module (40), the thermal module (50), and the controller (60), the first power module (100) including a first energy source type (200, 300, 400), and a second power module (100) removably connectable to the base (160), the motor module (40), the thermal module (50), and the controller (60), the second power module (100) including a second energy source type (200, 300, 400) different than the first energy source type.

[0011] In an exemplary embodiment, each of the first power module (100) and the second power module (100) may comprise a housing (102) enclosing an energy source (200, 300, 400), the housing (102) including a top surface (104), a bottom surface (106), an input interface (130), and an output interface (140), a lifting structure (116) secured to the housing (102), and at least one protrusion (108A-108B) extending from the bottom surface (106) in a first direction, the at least one protrusion (108A-108B) comprising a hole (110A-110B, 112A-112B) extending therethrough in a second direction, wherein the at least one arm (166A-166B, 170A-170B) isoperatively arranged to engage the hole (110A-110B, 112A-112B) to secure the housing (102) to the base (160).

[0012] In an exemplary embodiment, the second direction may be perpendicular to the first direction. In an exemplary embodiment, the at least one protrusion (108A-108B) may comprise a first protrusion (108A) and a second protrusion (108B) spaced apart from the first protrusion (108A). In an exemplary embodiment, the input interface (130) may comprise an energy port (136) for inputting energy into the energy source (200, 300, 400), and a data port (132, 136) for communicating with the energy source (200, 300, 400). In an exemplary embodiment, the output interface (140) may comprise a high voltage port (142) for outputting high voltage power from the energy source (200, 300, 400), a low voltage port (146) for outputting low voltage power from the energy source (200, 300, 400), a data port (146) for enabling communication between the mobile machine (10) and the energy source (200, 300, 400), and a fluid port (148) for circulating temperature regulating fluid from the mobile machine (10) to the energy source (200, 300, 400). In an exemplary embodiment, the first energy source type (200, 300, 400) may be a battery module (200), and the second energy source type (200, 300, 400) may be an internal combustion engine (300) or a hydrogen fuel cell (400).

[0013] The following will describe embodiments of the present disclosure, but it should be appreciated that the present disclosure is not limited to the described embodiments and various modifications of the disclosure are possible without departing from the basic principles. The scope of the present disclosure is therefore to be determined solely by the appended claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Various embodiments are disclosed, by way of example only, with reference to the accompanying schematic drawings below in which corresponding reference symbols indicate corresponding parts.

[0015] FIG. 1A is a top front perspective view of a mobile machine.

[0016] FIG. IB is a top plan view of the mobile machine shown in FIG. 1 A.

[0017] FIG. 1C is a side elevational view of the mobile machine shown in FIG. 1A.

[0018] FIG. 2A is a top left side perspective view of a first exemplary embodiment of the power module shown in FIG. 1 A.

[0019] FIG. 2B is a bottom right side perspective view of the power module shown in FIG. 1A.

[0020] FIG. 3A is a partial perspective detail view of the power module taken generally along DETAIL 3 A in FIG. 2A.

[0021] FIG. 3B is a front perspective view of the power module shown in FIG. 3A.

[0022] FIG. 4 is a cross-sectional view of the power module taken generally along line 4-4 in FIG. 2A.

[0023] FIG. 5 is a cross-sectional view of a second exemplary embodiment of the power module taken generally along line 5-5 in FIG. 2A.

[0024] FIG. 6 is a cross-sectional view of a third exemplary embodiment the power module taken generally along line 6-6 in FIG. 2A.

[0025] FIG. 7 is a top perspective view of the base shown in FIG. 1C, in an unlocked state.

[0026] FIG. 8 is a top perspective view of the base shown in FIG. 1C, in a locked state.

[0027] FIG. 9 is a bottom front perspective view of the power module connected to the base.

[0028] FIG. 10 is a perspective view of the controller shown in FIG. 1A.

[0029] FIG. 11 is a cross-sectional view of the controller taken generally along line 11-11 in FIG. 10.

[0030] FIG. 12 is a cross-sectional view of the controller taken generally along line 12-12 in FIG. 10.

[0031] FIG. 13 is a flow chart depicting operational steps for operating a mobile machine using an energy agnostic power system.DETAILED DESCRIPTION OF THE EMBODIMENTS

[0032] At the outset, it should be clearly understood that like reference numerals are intended to identify the same structural elements, portions, or surfaces consistently throughout the several drawing figures, as such elements, portions or surfaces may be further described or explained by the entire written specification, of which this detailed description is an integral part. Unless otherwise indicated, the drawings are intended to be read (e.g., cross-hatching, arrangement of parts, proportion, degree, etc.) together with the specification, and are to be considered a portion of the entire written description of this invention. As used in the following description, the terms “horizontal,” “vertical,” “left,” “right,” “up,” and “down,” as well as adjectival and adverbial derivatives thereof (e.g., “horizontally,” “rightwardly,” “upwardly,” etc.), simply refer to the orientation of the illustrated structure as the particular drawing figure faces the reader. Similarly,the terms “inwardly” and “outwardly” generally refer to the orientation of a surface relative to its axis of elongation, or axis of rotation, as appropriate.

[0033] Furthermore, it is understood that this disclosure is not limited to the particular methodology, materials, and modifications described and as such may, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to limit the scope of the claims.

[0034] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure pertains. It should be understood that any methods, devices, or materials similar or equivalent to those described herein can be used in the practice or testing of the example embodiments.

[0035] It should be appreciated that the term “substantially” is synonymous with terms such as “nearly,” “very nearly,” “about,” “approximately,” “around,” “bordering on,” “close to,” “essentially,” “in the neighborhood of,” “in the vicinity of,” etc., and such terms may be used interchangeably as appearing in the specification and claims. It should be appreciated that the term “proximate” is synonymous with terms such as “nearby,” “close,” “adjacent,” “neighboring,” “immediate,” “adjoining,” etc., and such terms may be used interchangeably as appearing in the specification and claims. The term “approximately” is intended to mean values within ten percent of the specified value.

[0036] Moreover, as used herein, the phrases “comprises at least one of’ and “comprising at least one of’ in combination with a system or element is intended to mean that the system or element includes one or more of the elements listed after the phrase. For example, a device comprising at least one of: a first element; a second element; and a third element, is intended to be construed as any one of the following structural arrangements: a device comprising a first element; a device comprising a second element; a device comprising a third element; a device comprising a first element and a second element; a device comprising a first element and a third element; a device comprising a first element, a second element and a third element; or a device comprising a second element and a third element. A similar interpretation is intended when the phrase “used in at least one of:” is used herein.

[0037] Referring now to the figures, FIG. 1A is a top front perspective view of mobile machine 10. FIG. IB is a top plan view of mobile machine 10. FIG. 1C is a side elevational view of mobile machine 10. In an exemplary embodiment, mobile machine 10 comprises frame orchassis 12, a traction system, for example tracks or wheels 16, and at least one work tool, for example bucket 20. In an exemplary embodiment, mobile machine 10 further comprises cab or cabin 14. In an exemplary embodiment, mobile machine 10 further comprises an actuation system, for example boom 22 and / or arm 24. In an exemplary embodiment, mobile machine 10 is an excavator; however, it should be appreciated that mobile machine 10 may comprise any mobile machine, for example, CTLs, bulldozers, agricultural tractors, cranes, backhoes, loaders, etc. Thus, while in this embodiment mobile machine 10 is an excavator, other types of mobile machines or vehicles with attached machinery or equipment that are self-propelled or mobile and that provide functionality beyond transport may be alternatives, including without limitation forklifts, skid steers, tractors, earthmovers, farm machinery, dump trucks, garbage trucks, mobile cranes, backhoe loaders, wheeled loaders, scrapers, graders, compactors, and other mobile construction equipment.

[0038] Mobile machine 10 comprises a plurality of control axes, for example axes A1-A5. Control axes are axes about which the mobile machine 10 is movable. Track(s) 16 is displaceable in circumferential direction CD1 about axis Al to drive mobile machine 10, for example, in axial direction AD. Arm 24 is displaceable in circumferential direction CD1 with respect to boom 22, for example via an actuator, about axis A2. Bucket 20 is displaceable in circumferential direction CD1 with respect to arm 24, for example via an actuator, about axis A3. Boom 22 is displaceable in circumferential direction CD1 with respect to frame 12, for example via an actuator, about axis A5. Frame 12, and thus boom 22, arm 24, and bucket 20, is displaceable in circumferential direction CD2 with respect to track 16 about axis A4. Thus, in the exemplary embodiment shown in FIGS. 1A-1C, mobile machine 10 comprises six control axes or degrees of freedom. In an exemplary embodiment, mobile machine 10 is a CTL or skid steer loader including four control axes. In an exemplary embodiment, mobile machine 10 further comprises a thumb hingedly connected to arm 24 or bucket 20 and displaceable about an axis. In an exemplary embodiment, mobile machine 10 further comprises a blade displaceably connected to frame 12 and displaceable about an axis. In an exemplary embodiment, mobile machine 10 further comprises a power take off or auxiliary drive shaft displaceable about an axis. Such additional features would add more control axes to mobile machine 10, for example seven, eight, nine, or ten control axes or degrees of freedom.

[0039] In an exemplary embodiment, mobile machine 10 further comprises platform or ledge 18 such that one or more power modules 100 may be removably connected to mobile machine 20, as will be described in greater detail below. Platform 18 may be fixedly secured to frame 12. In an exemplary embodiment, one or more bases or module attachments 160 are arranged on mobile machine 10, for example on platform 18, to facilitate removable connectability with one or more modules 100. In an exemplary embodiment, mobile machine 10 further comprises a cover (not shown) arranged to be removably connected to mobile machine such that it protects power modules 100, platform 160, motor module 40, thermal module 50, control module 60, and various other components from debris.

[0040] In an exemplary embodiment, mobile machine 10 further comprises hydraulic equipment 42. Hydraulic equipment 42 may comprise any number of components for operating various elements of mobile machine 10, for example, a hydraulic tank, a hydraulic pump servo drive, and a pump. Mobile machine 10 comprises motor module 40 which drives all hydraulic functions and / or each motion axes, for example hydraulic and / or mechanical motion axes of mobile machine 10. For example, motor module 40 drives the hydraulic pump to operate the various hydraulic components of mobile machine 10, such as the hydraulic cylinders that drive arm 24 of mobile machine 10 (e.g., for an excavator). Motor module 40 may also drive wheels or tracks directly, as well as actuators (e.g., electro-mechanical actuators). In an exemplary embodiment, motor module 40 comprises a 700 VDC, 150 kW ultra-efficient, regenerative capable electric motor. In an exemplary embodiment, motor module 40 is thermally managed, for example via thermal module 50. In an exemplary embodiment, motor module 40 is sound insulated. In an exemplary embodiment, motor module 40 comprises a sealed system that can be replaced in-field. In an exemplary embodiment, electric motor module 40 comprises internet of things (IoT) technology for motor performance monitoring and reporting. In an exemplary embodiment, hydraulic fluid utilized by the hydraulic pump is stored in the hydraulic tank. The hydraulic pump servo drive may provide a feedback signal from motor module 40 and / or the pump to a controller.

[0041] Thermal module 50 is operatively arranged to maintain power modules 100, motor module 40, and electronics at an optimum temperature. Thermal module 50 comprises ports 78A- 78B, as will be described in greater detail below. In an exemplary embodiment, thermal module 50 comprises a sealed system that can be replaced in-field. Thermal module 50 allows mobile machine 10 to operate in any temperature. Thermal module 50 provides thermal management, oractive cooling and heating to maintain component and cabin temperatures. Thermal module 50 may comprise one or more of a chiller, radiator, fan, pump, heater, and heat exchanger arranged to regulate fluid temperature and thus the temperature of components within mobile machine 10.

[0042] FIG. 2A is a top left side perspective view of power module 100. FIG. 2B is a bottom right side perspective view of power module 100. Power module 100 is operatively arranged to be removably connected to mobile machine 10. Power module 100 is operatively arranged to produce energy and output the energy, in an electrical form, to mobile machine 10. Power module 100 comprises housing 102 including top surface 104 and bottom surface 106. Power module 100 comprises input interface 130 and output interface 140.

[0043] Power module 100 comprises one or more protrusions extending from bottom surface 106, for example, protrusion 108 A and protrusion 108B. In an exemplary embodiment, and as shown, protrusion 108B is separated from protrusion 108A. Protrusions 108A-108B are fixedly secured to housing 102. Protrusion 108A comprises bottom surface 114A and at least one hole, for example, hole 110A and hole 112A. In an exemplary embodiment, holes 110A and 112A are through holes arranged between bottom surface 106 and bottom surface 114A. In an exemplary embodiment, hole 112A is spaced apart from hole 110A. In an exemplary embodiment, hole 110A is arranged proximate a first end of protrusion 108A and hole 112A is arranged proximate a second end of protrusion 108A. Holes 110A and 112A are operatively arranged to engage arms 166A- 166B and 170A-170B to secure power module 100 to base 160, as will be described in greater detail below.

[0044] Protrusion 108B comprises bottom surface 114B and at least one hole, for example, hole HOB and hole 112B. In an exemplary embodiment, holes HOB and 112B are through holes arranged between bottom surface 106 and bottom surface 114B. In an exemplary embodiment, hole 112B is spaced apart from hole 110B. In an exemplary embodiment, hole 110B is arranged proximate a first end of protrusion 108B and hole 112B is arranged proximate a second end of protrusion 108B. Holes 110B and 112B are operatively arranged to engage arms 166A-166B and 170A-170B to secure power module 100 to base 160, as will be described in greater detail below.

[0045] Power module 100 further comprises lifting structure 116. In an exemplary embodiment, lifting structure 116 extends from top surface 104 and comprises at least one hole. For example, lifting structure 116 comprises at least one flange section, for example, flange sections 118A-118D. Flange sections 118A-118D comprise one or more holes 120A-120D,respectively. Holes 120A-120D provide lifting points to be used to lift power module 100, for example, using forks on a forklift. In an exemplary embodiment, and as shown, flange sections 118A-118D are secured to lateral sides of housing 102 (i.e., the sides extending between top surface 104 and bottom surface 106). This enables power modules 100 to be stacked on top of each other, and flange sections 118A-118D prevent slippage between the stacked power modules 100.

[0046] FIG. 3A is a partial perspective detail view of a first embodiment of power module 100 taken generally along DETAIL 3A in FIG. 2A, and showing input interface 130. FIG. 3B is a partial front perspective view of input interface 130. FIG. 4 is a cross-sectional view of power module 100 taken generally along line 4-4 in FIG. 2A. Input interface 130 is operatively arranged for inputting energy into power module 100, as well as communicating with the energy source therein, and comprises port 132 (e.g., an electrical port compatible with a charging connection or charge gun). Port 132 is electrically connected to battery module 200 via one or more conduits 136. In an exemplary embodiment, conduits 136 comprise electrical conduit 136A (e.g., hot or lead), electrical conduit 136B (e.g., hot or lead), electrical conduit 136C (e.g., ground), electrical conduit 136D (e.g., neutral), and communications conduit 136E (e.g., data). Conduit 136 connects port 130 to battery module 200. In an exemplary embodiment, input interface 130 comprises cover 134 operatively arranged to protect port 132 from debris and other elements. In an exemplary embodiment, input interface 130 may further comprise a microswitch on cover 132 for safety purposes.

[0047] Output interface 140 is operatively arranged for outputting energy to mobile machine 10 and enabling communication between power module 100 and mobile machine 10. Output interface 140 comprises high voltage (HV) port 142, low voltage (LV) and / or data port 146, and one or more fluid ports 148, for example, fluid or coolant inlet port 148A, and fluid or coolant outlet port 148B. Output interface 140 is connected to battery module 200 via one or more conduits. For example, conduit 202 connects HV port 142 and LV port 146 to battery module 200, conduit 204 connects the data port 146 to battery module 200, and conduit 206 connects fluid ports 148 to battery module 200. Conduit 206 allows temperature-regulating fluid to be circulated in and / or around battery module 200. In an exemplary embodiment, output interface 140 further comprises an E-stop.

[0048] In an exemplary embodiment, power module 100 having battery module 200 may include one or more of the following status messages: actual voltage on 12 VDC bus; actual voltageon HV bus; nominal capacity (e.g., 70 or 140 KWh); battery effectiveness (actual capacity given age and pedigree); current temperatures (each battery pack, coolant, internal and externa ambient); bilge water sensor; state of charge (SoC); contactor status; pump status; passive radiator fan status; historical record (e.g., free form notes); and charging from the external port is in progress.

[0049] In an exemplary embodiment, power module 100 having battery module 200 may include one or more of the following control messages: ready to charge from vehicle bus, accept?; close HV contactors; over-ride onboard circulation pump control (i.e., because swap is imminent, pre-chilling or end of day); and over-ride onboard passive radiator fan control (i.e., because weather opportunity is present, swap is imminent, beginning or end of day related).

[0050] FIG. 5 is a cross-sectional view of a second exemplary embodiment of power module 100 taken generally along line 5-5 in FIG. 2A. As shown, power module 100 comprises combustion engine 300. Input interface 130 is operatively arranged for inputting energy into power module 100, as well as communicating with the energy source therein. Input interface 130 comprises port 132 (e.g., a data or communications port). Port 132 is connected to combustion engine 300 via one or more conduits 308. Input interface 130 further comprises port 136 for inputting fuel (e.g., gasoline, diesel fuel, hydrogen, etc.) into combustion engine 300, for example via conduit 310. Combustion engine 300 converts the fuel into electrical energy.

[0051] Output interface 140 is operatively arranged for outputting the electrical energy produced by combustion engine to mobile machine 10 and enabling communication between power module 100 and mobile machine 10. HV port 142 of output interface 140 is connected to combustion engine via conduit 302. LV and / or data port 146 of output interface 140 is connected to combustion engine 300 via conduit 304. Fluid port 148 of output interface 140 is connected to combustion engine 300 via conduit 306 in order to circulate temperature-regulating fluid in and / or around combustion engine 300. In an exemplary embodiment, power module 100 may further comprise exhaust vent 312 operatively arranged to direct exhaust gases outside of housing 102.

[0052] In an exemplary embodiment, power module 100 having diesel / gasoline combustion engine module 300 may include one or more of the following status messages: actual voltage on 12 VDC bus; diesel fuel level; oil pressure and temperature; engine temperature; coolant temperature; RPM; maintenance status (e.g., oil, oil filter, air filter, diesel exhaust fluid (DEF), etc.); DEF level; bilge water sensor; historical record (e.g., free form notes); contactor status; and TAME or other HV buck / boost status.

[0053] In an exemplary embodiment, power module 100 having diesel / gasoline combustion engine module 300 may include one or more of the following control messages: start / shut off engine; close contactors; control of TAME buck / boost; glow plug preheat; and operate in regenerate mode.

[0054] In an exemplary embodiment, power module 100 having hydrogen internal combustion engine module 300 may include one or more of the following messages, in addition to those listed above with respect to the diesel combustion engine: hydrogen tank pressure and temperature; and hydrogen flow rate.

[0055] FIG. 6 is a cross-sectional view of a third exemplary embodiment power module 100 taken generally along line 6-6 in FIG. 2A. As shown, power module 100 comprises hydrogen fuel cell module 400. Energy fuel cell module 400 generally comprises fuel cell 412 and hydrogen tank 418. Fuel cell 412 received hydrogen from hydrogen tank 418 via hydrogen supply conduit 420. Hydrogen may be returned to hydrogen tank 418 from fuel cell 412 via hydrogen return conduit 422. Power module 100 further comprises intake 414 such that oxygen from air outside of housing 102 may be supplied to fuel cell 412. Power module 100 may further comprise outlet 416 such that water vapor created by fuel cell 412 can be expelled from power module 100.

[0056] Hydrogen atoms from hydrogen gas tank 418 enter fuel cell 412 via conduit 420 at the anode, while oxygen is fed to the cathode of fuel cell 412 via conduit 414. In an exemplary embodiment, fuel cell 412 comprises a membrane coated with a catalyst. When the hydrogen molecules hit the catalyst, they’re split into hydrogen ions and electrons. The membrane lets positively charged hydrogen ions pass through, but not the negatively charged electrons, which instead flow through an electric circuit where the electric current is generated. At the cathode side, the hydrogen ions, electrons, and the oxygen in the air combine to produce heat. Fuel cell 412 may comprise a plurality (e.g., hundreds) of membranes stacked together.

[0057] Input interface 130 is operatively arranged for inputting energy into power module 100, as well as communicating with the energy source therein. Input interface 130 comprises port 132 (e.g., a data or communications port). Port 132 is connected to fuel cell 412 and / or hydrogen tank 418 via one or more conduits 408. Input interface 130 further comprises port 136 for inputting fuel (e.g., hydrogen) into hydrogen tank 418, for example via conduit 410. Hydrogen fuel cell module 400 converts the hydrogen into electrical energy.

[0058] Output interface 140 is operatively arranged for outputting the electrical energy produced by hydrogen fuel cell module 400 to mobile machine 10 and enabling communication between power module 100 and mobile machine 10. HV port 142 of output interface 140 is connected to fuel cell 412 via conduit 402. LV and / or data port 146 of output interface 140 is connected to fuel cell 412 via conduit 404. Since a byproduct of hydrogen fuel cell module 400 is water, cooling fluid may not be needed. However, if needed, fluid port 148 of output interface 140 may be connected to hydrogen fuel cell module in order to circulate temperature-regulating fluid therein and / or ther ear ound.

[0059] FIG. 7 is a top perspective view of base or mechanical retention platform 160, in an unlocked state. Base 160 is arranged on mobile machine, for example on frame 12 or platform 18. Base 160 comprises frame 162 and at least one arm displaceably connected thereto, for example, arm 166A, arm 166B, arm 170A, and arm 170B. In an exemplary embodiment, arm 166A is slidably arranged inside of tube 164A. Arm 166A comprises extension 168A operatively arranged to engage hole or slot 167A in tube 164A. Extension 168 A extends through slot 167A in direction D3. Arm 166A is displaceable in direction DI and direction D2 with respect to tube 164 A and frame 162. In an exemplary embodiment, and as shown in FIG. 7, in the unlocked state arm 166A resides completely within tube 164A (i.e., does not extend out of the end of tube 164A).

[0060] In an exemplary embodiment, arm 170A is slidably arranged inside of tube 164A. Arm 170A comprises extension 172A operatively arranged to engage hole or slot 171A in tube 164A. Extension 172A extends through slot 171 A in direction D3. Arm 170A is displaceable in direction DI and direction D2 with respect to tube 164A and frame 162. In an exemplary embodiment, and as shown in FIG. 7, in the unlocked state arm 170A resides completely within tube 164A (i.e., does not extend out of the end of tube 164A).

[0061] In an exemplary embodiment, arm 166B is slidably arranged inside of tube 164B. Arm 166B comprises extension 168B operatively arranged to engage hole or slot 167B (not shown) in tube 164B. Extension 168B extends through slot 167B in direction D4. Arm 166B is displaceable in direction DI and direction D2 with respect to tube 164B and frame 162. In an exemplary embodiment, and as shown in FIG. 7, in the unlocked state arm 166B resides completely within tube 164B (i.e., does not extend out of the end of tube 164B).

[0062] In an exemplary embodiment, arm 170B is slidably arranged inside of tube 164B. Arm 170B comprises extension 172B operatively arranged to engage hole or slot 171B (notshown) in tube 164B. Extension 172B extends through slot 17 IB in direction D4. Arm 170B is displaceable in direction DI and direction D2 with respect to tube 164B and frame 162. In an exemplary embodiment, and as shown in FIG. 7, in the unlocked state arm 172B resides completely within tube 164B (i.e., does not extend out of the end of tube 164B). In an exemplary embodiment, tubes 164A and 164B are arranged on a top surface of frame 162. In an exemplary embodiment, tube 164B is spaced apart from tube 164A in a direction perpendicular to direction DI, for example, direction D4.

[0063] Base 160 comprises spring or tension element 174A operatively arranged to bias arms 166A and 170A toward a position, for example, toward an unlocked state as shown in FIG.7. In an exemplary embodiment, spring element 174A is arranged to bias arms 166A and 170A toward the locked state shown in FIG. 8. Spring element 174A comprises a first end connected to extension 168A and a second end connected to extension 172A. Base 160 comprises spring or tension element 174B operatively arranged to bias arms 166B and 170B toward a position, for example, toward an unlocked state as shown in FIG. 7. In an exemplary embodiment, spring element 174B is arranged to bias arms 166B and 170B toward the locked state shown in FIG. 8. Spring element 174B comprises a first end connected to extension 168B and a second end connected to extension 172B.

[0064] Base 160 may further comprise plate 180 arranged on the top surfaces of tube 164A and tube 164B. One or more rollers 184 are rotatably connected to frame 162 and are operatively arranged to extend through respective holes 182 in plate 180. Rollers 184 are operatively arranged to facilitate displacement of power module 100 in direction D3 and direction D4 relative to frame 162, for example, to align arms 166A-166B and 170A-170B with holes 110A-110B and 112A- 112B. In an exemplary embodiment, rollers 184 may be raised and lowered relative to plate 180. For example, rollers 184 may be lowered such that bottom surface 106 of power module 100 engages plate 180 (see FIG. 8). In an exemplary embodiment, base 160 may automatically mate the electrical and coolant connections between mobile machine 10 and power modules 100.

[0065] FIG. 8 is a top perspective view of base 160, in a locked state. FIG. 9 is a bottom front perspective view of power module 100 connected to the base 160. To form the locked state of base 160, arms 166A-166B are displaced in direction DI with respect to tubes 164A-164B, respectively, such that arms 166A-166B extend out of the first end of tubes 164A-164B, respectively. Also, arms 170A-170B are displaced in direction D2 with respect to tubes 164A-164B, respectively, such that arms 170A-170B extend out of the first end of tubes 164A-164B, respectively. Arms 166A-166B and 170A-170B may be displaced using any suitable means, for example, hydraulic and / or electric actuators.

[0066] To secure power module 100 to base 160, power module 100 is arranged on top of base 160 such that bottom surface 106 is engaged with rollers 184 and / or plate 180. Protrusions 108A-108B are arranged on either side of the ends of tubes 164A-164B. Power module 100 is displaced in direction D3 or D4 until holes 110A-110B and 112A-112B are aligned with arms 166A-166B and 170A-170B. Once aligned, arms 166A-166B are displaced in direction DI and arms 170A-170B are displaced in direction D2 such that they extend through their respective aligned holes 110A-110B and 112A-112B. To remove power module 100 from base 160, arms 166A-166B are displaced in direction D2 and arms 170A-170B are displaced in direction DI such that they disengage respective holes 110A-110B and 112A-112B, at which point power module 100 can be removed from base 160.

[0067] FIG. 10 is a perspective view of controller 60. FIG. 11 is a cross-sectional view of controller 60 taken generally along line 11-11 in FIG. 10. FIG. 12 is a cross-sectional view of controller 60 taken generally along line 12-12 in FIG. 10. Controller 60 is arranged as an interface between mobile machine 10 and power module 100. For example, controller 60 may act as a power distribution unit for both HV and LV power to mobile machine 10, and a battery management system (BMS). Controller 60 comprises housing 62. In an exemplary embodiment, controller 60 comprises flange 64 arranged to facilitate connection controller 60 to mobile machine 100. Controller 60 comprises HV power port 68 operatively arranged to be electrically connected to HV power port 144 on power module 100. HV power port 68 is connected to various components of mobile machine 10 that require HV power, for example, motor module 40. HV power port 68 may be connected to a power distribution bus.

[0068] In an exemplary embodiment, controller 60 comprises LV power and / or communications port 66 operatively arranged to be connected to LV power and / or communications port 146 on power module 100. Port 66 is connected to various components of mobile machine 10 that require LV power, for example, electronic components in cab 14. Port 66 also provides the data connection between mobile machine 10 and power module 100. This data connection is important because it allows mobile machine 10, for example an operator in cab 14, to monitor the status of power module 100 (e.g., remaining charge, remaining fuel, temperature,etc ). The data connection also allows mobile machine 10 to perform a “handshake” such that mobile machine 10 can adequately identify the form of energy source of power module 100 and modulate / regulate it accordingly.

[0069] In an exemplary embodiment, controller 60 comprises one or more fluid ports, for example port 78A and port 78B. Ports 78A-78B are operatively arranged to be connected to ports 148A-148B of power module 100. Ports 78A-78B are connected to a temperature-regulating fluid reservoir on mobile machine 10. For example, a pump arranged on mobile machine 10 circulates the temperature-regulating fluid from a reservoir out of mobile machine 10 via port 78A and into power module 100 via port 148 A, and out of power module 100 via port 148B and back into mobile machine 10 via port 78B, where it can then be circulated through thermal module 50 for temperature regulation (i.e., via a chiller, radiator, heater, heat exchanger, etc.).

[0070] Controller 60 may further comprise ports 70A-70B. Controller 60 may further comprise ports 72A-72B. Controller 60 may further comprise ports 74A-74B. Controller 60 may further comprise port 76. Controller 60 may further comprise terminals 80.

[0071] In an exemplary embodiment, controller 60 further comprises loT board 82. loT board 82 comprises a circuit operatively arranged to facilitate interaction with controller 60. For example, loT board 82 may comprise one or more of a programming interface to program the controller 60 from a computer, a power circuit used to provide stable direct current (DC) power to the microcontroller, input components (e.g., buttons, switches, etc.), output components such as light emitting diodes (LEDs), and various input / output (I / O) pins used for compatibility with sensors, motors, screens, and any other components.

[0072] In an exemplary embodiment, controller 60 may further comprise multiple sets of HV contactors 84.

[0073] In an exemplary embodiment, controller 60 comprises one or more fuses 86. Fuse 86 is an electrical safety device that operates to provide overcurrent protection of the various electrical circuits in mobile machine 10. In an exemplary embodiment, controller 60 further comprises BMS 88.

[0074] In an exemplary embodiment, controller module 60 is operatively arranged to monitor temperature and weather to ensure best performance of mobile machine 10. Controller module 60 is capable of connecting wirelessly to devices, such as a smartphone or a graphic user interface (GUI) in cab 14 such that the operator can monitor various components of mobilemachine 10, track work progress and current on-site remaining power, and, if necessary, order additional power modules 100 to be delivered to the worksite. Controller module 60 can further track performance over time to improve power estimate accuracy (i.e., how power is used based on machine size, work being performed, terrain, material being moved, weather conditions, etc.). For example, a worksite comprising a terrain having a substantial amount of clay may require more power than a worksite comprising only soil. Controller module 60 may further track tonnage moved, area prepped, and additional operational data. All of the data tracked by controller module 60 may be stored either locally or transmitted to a remote location for processing and / or storage. In an exemplary embodiment, controller module 60 comprises a processor and / or a wireless transceiver.

[0075] FIG. 13 shows flow chart 500 depicting operational steps for operating mobile machine 10 using an energy agnostic power system.

[0076] In step 502, a first power module 100 is connected to mobile machine 10. Specifically, first power module 100 is secured to base 160, as described above. After securing first power module 100 to base 160, first power module 100 is connected to controller 60 via one or more conduits as described above. First power module 100 comprises a first type of energy source, for example, battery module 200.

[0077] In step 504, first power module 100 is removed from mobile machine 10. Specifically, first power module 100 is disconnected from controller 60. First power module 100 is disconnected from base 160 by retracting arms 166A-166B and 170A-170B, as described above.

[0078] In step 506, a second power module 100 is connected to mobile machine 10. Specifically, second power module 100 is secured to base 160, as described above. After securing second power module 100 to base 160, second power module 100 is connected to controller 60 via one or more conduits as described above. Second power module 100 comprises a second type of energy source that is different from the first type of energy source of first power module 100, for example, combustion engine 300.

[0079] In an exemplary embodiment, power modules 100 of the present disclosure all comprise the same coolant, electrical / power, communications, and mechanical interface requirements to guarantee interchangeability, no matter the energy source arranged therein. In an exemplary embodiment, power modules 100 have the same exterior dimensions, mechanical lifting points, mechanical retention interface geometry, weight, and / or center of gravity. Mobile machine10 is capable of recognizing the energy source of the connected power module 100, share this information with the operator, and have enhanced functionality and options corresponding to and appropriate to the energy source loaded at that moment in time. Mobile machine 10 and its controller is configured to accept and operate with various types of energy sources or modules (e.g., battery, diesel or gasoline or hydrogen internal combustion engine, hydrogen fuel cell, etc.).

[0080] In an exemplary embodiment, mobile machine 10 comprises a plurality of bases 160 compatible with power modules 100 of various energy sources. A controller will perform a handshake between the connected power module 100 and the mobile machine 10, and mobile machine 10 will choose to accept it into the overall system or reject it. In an exemplary embodiment, whether power module 100 is accepted or rejected, the GUI at the operator station on mobile machine 10 (e g., cab 14) will provide a visual representation of the machine indicating which docks are populated with which types of energy module. Thus, multiple power modules 100 of different energy sources could be connected to the same mobile machine 10 at the same time, providing electrical power at the same time.

[0081] In an exemplary embodiment, for modules power modules 100 that have been accepted by mobile machine 10, a sub menu may be accessed by the operator by selecting an icon on the GUI for any individual power module. The sub menu may provide the status from and control of the individual modules, allowing the operator to make decisions and take actions based on how the day’s work is progressing and what work remains to be done.

[0082] Programmed controllers may reside on both power modules 100 and mobile machine 10, and may be updated at any time, for example, as new power module types become available or new features are designed for a particular type of energy module. In an exemplary embodiment, mobile machine 10 and power modules 100 are loT connected, and thus the controllers thereon are easily updatable.

[0083] In an exemplary embodiment, mobile machine 10 further comprises one or more harnesses. The harness may include at least one of an electrical conduit, a communications, conduit, and a fluid conduit. The harness is operatively arranged to quickly and efficiently connect removable power modules 100 to a controller or interface of mobile machine 10.

[0084] The system and method of the present disclosure may be used to electrically power a mobile machine previously powered with a diesel engine using cleaner energy sources and without the cost and waste of purchasing an entirely new machine. Additionally, the amount ofinstalled energy is not fixed, the mobile machine can be powered by multiple energy sources, and the energy sources will be recognized by the mobile machine.

[0085] This disclosure has been described in detail with particular reference to an embodiment, but it will be understood that variations and modifications can be effected within the spirit and scope of the disclosure. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restrictive. The scope of the disclosure is indicated by the appended claims, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced therein.

Claims

CLAIMSWhat is claimed is:

1. A method of operating a mobile machine, comprising: connecting a first power module to the mobile machine, the first power module including a first energy source type; removing the first power module from the mobile machine; and connecting a second power module to the mobile machine, the second power module including a second energy source type, different than the first energy source type.

2. The method as recited in claim 1, wherein the step of connecting the first power module to the mobile machine comprises: mechanically connecting the first power module to the mobile machine; electrically connecting the first power module to the mobile machine; and fluidly connecting the first power module to the mobile machine.

3. The method as recited in claim 2, wherein the step of mechanically connecting the first power module to the mobile machine comprises: arranging the first power module on a base; and extending at least one arm arranged in the base through a hole in the power module.

4. The method as recited in claim 3, wherein the step of arranging the first power module on the base comprises: arranging the first power module on a plurality of rollers, the plurality of rollers being rotatably connected to the base; and displacing the first power module along the base to align the at least one arm with the hole.

5. The method as recited in claim 2, wherein the step of electrically connecting the first power module to the mobile machine comprises:connecting a high voltage port of the first power module to a power distribution unit of the mobile machine; connecting a low voltage port of the first power module to the power distribution unit; and connecting a communications port of the first power module to a controller of the mobile machine.

6. The method as recited in claim 5, wherein the step of fluidly connecting the first power module to the mobile machine comprises: connecting a first inlet port and a first outlet port of the first power module to a second inlet port and a second outlet port of the mobile machine, wherein the second inlet port and second outlet port are fluidly connected to a thermal module for regulating the temperature of fluid.

7. The method as recited in claim 1, wherein: one of the first energy source type and the second energy source type is a battery module; and the other of the first energy source type and the second energy source type is a combustion engine.

8. An energy agnostic mobile machine, comprising: a chassis; a traction system; at least one work tool; a thermal module; a motor module; a pump module; a controller; and a base operatively arranged for removably mounting a plurality of power modules, the base comprising: a frame connected to the chassis; a plate connected to the frame; and at least one arm displaceable with respect to the frame and plate.

9. The energy agnostic mobile machine as recited in claim 8, wherein: the base further comprises a tube connected to the frame; and the at least one arm is displaceable within the tube.

10. The energy agnostic mobile machine as recited in claim 9, wherein: in an unlocked state of the base, the at least one arm does not extend out of an end of the tube; and in a locked state of the base, the at least one arm extends out of the end of the tube.

11. The energy agnostic mobile machine as recited in claim 9, wherein the at least one arm comprises: a first arm arranged at a first end of the tube; and a second arm arranged at a second end of the tube.

12. The energy agnostic mobile machine as recited in claim 11, further comprising a spring element operatively arranged to bias the first arm and the second arm away from each other towards a locked state of the base.

13. The energy agnostic mobile machine as recited in claim 8, wherein the base further comprises a plurality of rollers rotatably connected to the frame.

14. The energy agnostic mobile machine as recited in claim 13, wherein each roller of the plurality of rollers extends through a respective hole in the plate.

15. The energy agnostic mobile machine as recited in claim 8, wherein the plurality of power modules comprises: a first power module removably connectable to the base, the motor module, the thermal module, and the controller, the first power module including a first energy source type; anda second power module removably connectable to the base, the motor module, the thermal module, and the controller, the second power module including a second energy source type different than the first energy source type.

16. The energy agnostic mobile machine as recited in claim 15, wherein each of the first power module and the second power module comprise: a housing enclosing an energy source, the housing including: a top surface; a bottom surface; an input interface; and an output interface; a lifting structure secured to the housing; and at least one protrusion extending from the bottom surface in a first direction, the at least one protrusion comprising a hole extending therethrough in a second direction; wherein the at least one arm is operatively arranged to engage the hole to secure the housing to the base.

17. The energy agnostic mobile machine as recited in claim 16, wherein the second direction is perpendicular to the first direction.

18. The energy agnostic mobile machine as recited in claim 16, wherein the at least one protrusion comprises a first protrusion and a second protrusion spaced apart from the first protrusion.

19. The energy agnostic mobile machine as recited in claim 16, wherein the input interface comprises: an energy port for inputting energy into the energy source; and a data port for communicating with the energy source.

20. The energy agnostic mobile machine as recited in claim 16, wherein the output interface comprises:a high voltage port for outputting high voltage power from the energy source; a low voltage port for outputting low voltage power from the energy source; a data port for enabling communication between the mobile machine and the energy source; and a fluid port for circulating temperature regulating fluid from the mobile machine to the energy source.

21. The energy agnostic mobile machine as recited in claim 15, wherein: the first energy source type is a battery module; and the second energy source type is an internal combustion engine or a hydrogen fuel cell.

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