Interchangeable trolley module for electric vehicle

Abstract

A trolley module (105) for an electric vehicle (100) includes a battery (110), a trolley system adapter (115), and a trolley supply unit controller (1415) configured to modulate electrical power received from a trolley system via the trolley module (105). The trolley supply unit controller (1415) is configured to, in a first mode of operation, deliver power collected via the trolley system adapter (115) to the vehicle (100) to propel the vehicle and, in a second mode of operation, deliver power directly from the battery (110) to propel the vehicle beyond catenary lines of a trolley system.

Description

INTERCHANGEABLE TROLLEY MODULE FOR ELECTRIC VEHICLECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 63 / 697,860, filed September 23, 2024, and entitled “Interchangeable Trolley Module for Electric Vehicle,” the entire disclosure of which is incorporated herein by reference.TECHNICAL FIELD

[0002] The present disclosure relates broadly to electric vehicles, and more specifically to electric vehicles having a battery pack that is interchangeable with a trolley module.BACKGROUND

[0003] Commonly owned U.S. Application No. 15 / 908,802, filed February 28, 2018, now U.S. Patent No. 10,668,830, issued June 2, 2020, describes a method and system for mounting and dismounting batteries from an electric vehicle, and swapping one battery for another. The entire disclosure of U.S. Application No. 15 / 908,802 is incorporated herein by reference.

[0004] Commonly owned U.S. Application No. 17 / 033,971 , filed September 28, 2020, now U.S. Patent No. 11 ,597,294, issued March 7, 2023, describes a battery connection mechanism for an electric vehicle. The entire disclosure of U.S. Application No. 17 / 033,971 is incorporated herein by reference.

[0005] Commonly owned U.S. Application No. 16 / 839,336, filed April 3, 2020, now U.S. Patent No. 11 ,241 ,974, issued February 8, 2022, describes a method and system for mounting and dismounting a battery pack and trolley module that areinterchangeable with one another. The entire disclosure of U.S. Application No. 16 / 839,336 is incorporated herein by reference.

[0006] In vehicles powered solely and at least partially with electricity, the sources of electricity may be a fuel engine combined with a generator, a battery, or a combination of both. In the subsurface mining environment, advances in electric and clean energy alternatives to traditional diesel machines require adaptability as mine operators transition from traditional diesel machines or trolley powered electric machines. While fully electric machines become more available with on-board energy sources in the form of heavy-duty battery packs, in some applications, it is even more advantageous to provide interchangeable energy sources for the electric machines.

[0007] Trolley systems are known energy sources for electric vehicles. They provide energy from catenary lines located above, which facilitates zero emission operation. Trolley trucks are a known application in both open pit mines and underground mines. A trolley mining truck is generally desired to be able to drive beyond the confines of the catenary lines. Some trolley trucks utilize internal combustion engines for propulsion beyond the catenary lines. Applicant’s own U.S. Patent No. 11 ,241 ,974 discloses a vehicle that includes a battery pack and a trolley module that are interchangeable with one another. These existing systems require either to have an internal combustion engine or to swap out the trolley module for a battery pack in order to drive beyond the catenary lines.

[0008] It would be desirable to be able to drive beyond the catenary lines without having to implement an internal combustion engine or otherwise swap out the trolley module with a battery pack.SUMMARY

[0009] Various embodiments of an electric vehicle are disclosed. The embodiments describe electric mining vehicles which can be battery powered or powered by a conventional trolley system with electrified catenary cables or rails supplied in a subsurface mine. That is, the vehicle may comprise a system that includesa battery pack and a trolley module that is interchangeable with the battery pack. With the trolley module fitted, the vehicle is enabled to be powered by a trolley system. When driving offline, the vehicle may utilize the conventional battery pack and when driving on the trolley line, the vehicle may utilize the trolley module. Further, the trolley module may itself include a battery, and thus, with the trolley module installed, the vehicle may be capable of off-line operation beyond catenary lines, at least for some distance.

[0010] In one aspect, the present disclosure is directed to a trolley module for an electric vehicle. The trolley module may include a battery, a trolley system adapter, and a trolley supply unit controller configured to modulate electrical power received from a trolley system via the trolley module. The trolley supply unit controller is configured to, in a first mode of operation, deliver power collected via the trolley system adapter to the vehicle to propel the vehicle and, in a second mode of operation, deliver power directly from the battery to propel the vehicle beyond catenary lines of a trolley system.

[0011] In another aspect, the present disclosure is directed to an electric vehicle including a drive system configured to operate on electrical power; a receptacle configured to receive a replaceable power unit; and a trolley module that is configured to be removably mounted in the receptacle of the vehicle and adapted to power the drive system of the vehicle. The trolley module includes a trolley supply unit controller configured to modulate electrical power received from a trolley system via the trolley module.

[0012] In another aspect, the present disclosure is directed to a system for supplying energy to an electric vehicle. The system includes a battery pack configured to be removably mounted on an electric vehicle and adapted to power a drive system of the vehicle, and a trolley module configured to be removably mounted on the vehicle and adapted to receive power from a trolley system and use it to power the drive system of the vehicle. The trolley module is interchangeable with the battery pack. In addition, the trolley module includes a trolley supply unit controller configured to modulate electrical power received from the trolley system via the trolley module, wherein the trolley supply unit controller is configured to deliver power to the vehicle in a mannerthat is indecipherable, by the vehicle, from power delivered to the vehicle by the battery pack.

[0013] Other systems, methods, features, and advantages of the disclosed systems and methods will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description and this summary, be within the scope of the disclosed systems and methods, and be protected by the following claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The disclosed systems and methods can be better understood with reference to the following figures and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the disclosed systems and methods. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.

[0015] FIG. 1 is a schematic front perspective view illustration of a subsurface mining machine having a trolley module and configured to be powered by overhead electrified catenary cables or rails;

[0016] FIG. 2 is a schematic front perspective view illustration of the trolley module from the vehicle shown in FIG. 1 ;

[0017] FIG. 3 is a schematic front perspective view illustration of the trolley module of FIG. 2 without its external cage;

[0018] FIG. 4 is an electrical schematic of the trolley module illustrating the management of electrical power between the catenary lines and the vehicle for use with a two-phase DC trolley system;

[0019] FIG. 5 is an electrical schematic of the trolley module illustrating the management of electrical power between the catenary lines and the vehicle for use with a three-phase AC trolley system according to a first embodiment;

[0020] FIG. 6 is an electrical schematic of the trolley module illustrating the management of electrical power between the catenary lines and the vehicle for use with a three-phase AC trolley system according to a second embodiment;

[0021] FIG. 7 is a schematic front view illustration of the trolley module;

[0022] FIG. 8 is a schematic rear view illustration of the trolley module;

[0023] FIG. 9 is a schematic left side view illustration of the trolley module;

[0024] FIG. 10 is a schematic right side view illustration of the trolley module;

[0025] FIG. 11 is a schematic top view illustration of the trolley module;

[0026] FIG. 12 is a schematic bottom view illustration of the trolley module;

[0027] FIG. 13 is a schematic system diagram of the electrical system of the vehicle with a battery pack attached to the vehicle;

[0028] FIG. 14 is a schematic system diagram of the electrical system of the vehicle with the trolley module attached to the vehicle; and

[0029] FIG. 15 is a schematic system diagram of a trolley supply unit controller of the trolley module.DETAILED DESCRIPTION

[0030] The present disclosure is generally directed to electric, sub-surface mining vehicles. However, it will be understood that the concepts disclosed herein may be applicable to any type of electric land vehicle. In some subsurface mines, electric vehicles are powered by a wired connection such as a catenary (trolley) line or a conductive rail of a track or the like. This confines a vehicle to use on the trolley line. Therefore, the presently disclosed vehicle comprises a system that includes both a battery pack and a trolley module that is interchangeable with the battery pack. Therefore, the disclosed electric vehicles can be battery powered for “offline” travel or powered by a conventional trolley system with electrified catenary cables or rails supplied in a subsurface mine. In addition, the trolley module may include its own battery pack, and thus, a vehicle equipped with the trolley module may operate viapower from catenary lines or on its own beyond the catenary lines without having to swap out the trolley module for a separate battery pack.

[0031] An exemplary vehicle and battery mounting and dismounting method are described in U.S. Application No. 15 / 908,802 (U.S. Patent No. 10,668,830). The current disclosure contemplates the use of a trolley module that has a common form factor with (and is therefore interchangeable with) a battery pack, both of which are configured to work with the drive system of the vehicle. Accordingly, the trolley module may be mounted and dismounted using the same system and method as the battery pack.

[0032] It will be understood that a battery pack may include two or more battery units. It will also be understood that each “battery” may include multiple battery “cells.”

[0033] For purposes of this disclosure, the term “form factor,” with respect to the battery pack and trolley module, shall refer to the overall length, overall width, and overall height of the respective components, as well as other dimensions. In other words, a battery pack and trolley module that share substantially the same form factor both fit within the confines of the same recess, receptacle, or other receiving portion of the vehicle. Due at least in part to this common form factor, the disclosed battery pack and trolley module are interchangeable with one another in terms of fitment and attachment to the vehicle.

[0034] In general, as used herein, "electric vehicle" refers to a vehicle that uses electrical power for propulsion purposes, at least in one mode of operation. Thus, electric vehicles include all-electric vehicles (e.g., a vehicle with a traction motor and only an onboard electrical energy storage device or mechanism for receiving electric energy from an off-board source, such as an overhead catenary or powered rail), hybrid-electric vehicles (e.g., a vehicle with a traction motor, an energy storage device, hydraulic propulsion, and an internal combustion engine, fuel cell, or the like for charging the energy storage device and / or directly generating power for running the traction motor), dual-mode vehicles (e.g., a vehicle with an engine-only mode ofoperation and an electricity-only mode of operation, or a vehicle with a first mode of operation where traction electricity is provided by an engine and a second mode of operation where traction electricity is provided by another source), diesel-electric and other engine-electric vehicles (e.g., a vehicle with an engine that generates electrical power for running a traction motor), and combinations and variants thereof. Electric vehicles may have one traction motor, or plural traction motors; "traction motor" refers to a motor of sufficient size and capacity to move a vehicle of sufficient size for the designated operation.

[0035] An exemplary electric vehicle is disclosed. The vehicle may include a drive system configured to operate on electrical power and a receptacle configured to receive a replaceable power unit. The vehicle may also include a first power unit in the form of a battery pack that is configured to be removably mounted in the receptacle of the vehicle and adapted to power the drive system of the vehicle. Further, the vehicle may include a trolley module that is configured to be removably mounted in the receptacle of the vehicle and adapted to power the drive system of the vehicle, wherein the trolley module is interchangeable with the battery pack. The trolley module includes a trolley supply unit controller configured to modulate electrical power received from a trolley system via the trolley module, wherein the trolley supply unit controller is configured to deliver power to the vehicle in a manner that is indecipherable, by the vehicle, from power delivered to the vehicle by the battery pack.

[0036] FIG. 1 is a schematic front perspective view illustration of a subsurface mining machine having a trolley module and configured to be powered by overhead electrified catenary cables or rails. FIG. 1 illustrates an electric vehicle 100. As shown in FIG. 1 , in some embodiments, electric vehicle 100 may include an operator cab 101. It will be understood that the disclosed interchangeable power units may be implemented on a remotely operated vehicle (ROV) or on an autonomous vehicle. In such embodiments, vehicle 100 may be provided without an operator cab. It will also be noted that, in such embodiments that lack an operator cab, the space that wouldotherwise be occupied by the operator cab could be utilized for portions of the battery and / or trolley module.

[0037] Vehicle 100 has a drive system that is configured to drive wheels, including front wheels 102 and / or rear wheels 103. Also, in some embodiments, vehicle 100 may be a dump truck. Accordingly, in such embodiments, as shown in FIG. 1 , vehicle 100 may include a bed or dump body 104 for carrying a load of material. Still, in some embodiments, vehicle 100 may be a load-haul-dump (LHD) vehicle.

[0038] As shown in FIG. 1 , vehicle 100 may include a removable trolley module 105, which may be interchangeable with a battery pack (not shown). Trolley module 105 may include a battery 110, and a trolley system adapter 115. With trolley module 105 installed / mounted, vehicle 100 may be powered by catenary lines or rails via contact between contact shoes at the ends of trolley poles 120 connected to the top surface of trolley module 105. It will be understood that the connection between trolley module 105 and the trolley system may have any suitable type of current collector. For example, in some embodiments, the trolley module may include a pantograph.

[0039] It will also be understood that the battery of the trolley module may, in some embodiments, be a battery pack itself, i.e. , consisting of two or more battery units. In some embodiments, these units may be individually operable.

[0040] FIG. 2 is a schematic front perspective view illustration of the trolley module from the vehicle shown in FIG. 1 . As shown in FIG. 2, a cage or housing 200 may house battery 110 and trolley system adapter 115. FIG. 3 is a schematic front perspective view illustration of the trolley module of FIG. 2 without its external cage 200.

[0041] FIG. 4 is an electrical schematic of the trolley module illustrating the management of electrical power between the catenary lines and the vehicle for use with a two-phase DC trolley system. As shown, two trolley poles 120 may be utilized since the system is a two-phase system. Progressing from trolley poles 120, power received by trolley system adapter 115 of the trolley module first passes through a plurality of DC fuses 400. Next, the system includes a trolley supply isolation switch 405 for selectivecutting of power received by the trolley module. The trolley system adapter 115 further includes polarity check contactors 410.

[0042] Trolley system adapter 115 may also include a plurality of Trolley Converter Units (TCU's) 420, which include DC to DC converters. The power received from the catenary lines is fed through TCU’s 420. The power converted by TCU’s 420 is then fed in parallel with power from battery 110 to a vehicle interface 425 via a common DC bus.

[0043] The system also includes two or more Low Voltage Units (LVUs) 415. LVU1 and LVU2 include DC to DC converters. Notably, the LVUs receive DC power from the common DC bus (via circuit breakers F10 and F11 ) and convert the DC power into lower voltage for powering smaller loads (e.g., lights, trolley actuators, etc.).

[0044] FIG. 5 is an electrical schematic of the trolley module illustrating the management of electrical power between the catenary lines and the vehicle for use with a three-phase AC trolley system according to a first embodiment. As shown in FIG. 5, the trolley module may include three trolley poles 120 in order to be compatible with a three-phase trolley system. As with the two-phase system, the three-phase system includes trolley system adapter 115, which includes a trolley supply isolation switch 500. As also shown in FIG. 5, the trolley system adapter 115 further includes a step-down transformer 505, as well as a pair of line filters, in this case LCL filters 510.

[0045] The system includes one or more active rectifiers. For example, trolley system adapter 115 may include a plurality of Trolley Converter Units (TCU’s) 520, which include AC to DC converters. The power received from the catenary lines is converted by TCU’s 520 and then fed in parallel with power from battery 110 to a vehicle interface 425 via a common DC bus.

[0046] The system also includes at least one Low Voltage Unit (LVU) 515. LVU 515 includes a DC to DC converter. Notably, LVU 515 receives DC power from the common DC bus (via fuses F1 ) and converts the DC power into lower voltage for powering smaller loads (e.g., lights, trolley actuators, etc.).

[0047] FIG. 6 is an electrical schematic of the trolley module illustrating the management of electrical power between the catenary lines and the vehicle for use with a three-phase AC trolley system according to a second embodiment. As shown in FIG. 6, the trolley module may include three trolley poles 120 in order to be compatible with the three-phase trolley system. Also, in this embodiment the trolley system adapter 115 includes a trolley supply isolation switch 600. As also shown in FIG. 6, the trolley system adapter 115 includes a line filter 605, in this case an L filter (inductor only). In other embodiments, an LC filter, which includes a series of inductor and shunt capacitor, could be used. Alternatively, an LCL filter, which consists of a series of inductor, shunt capacitor, and series inductor, could be used.

[0048] In the system shown in FIG. 6, trolley system adapter 115 includes a rectifier unit 610, which may be a passive rectifier (e.g., a diode or a thyristor bridge), and may be configured to convert AC to DC. In some cases, this embodiment may implement an active rectifier as with the embodiment discussed above.

[0049] Trolley system adapter 115 may also include a plurality of Trolley Converter Units (TCU’s) 620, which include DC to DC converters. The power received from catenary line is converted by TCU’s 620 and is then fed in parallel with power from battery 110 to vehicle interface 425 via a common DC bus.

[0050] The system also includes at least one Low Voltage Unit (LVU) 615. LVU 615 includes a DC to DC converter. Notably, LVU 615 receives DC power from the common DC bus (via fuses F1 ) and converts the DC power into lower voltage for powering smaller loads (e.g., lights, trolley actuators, etc.).

[0051] FIG. 7 is a schematic front view illustration of trolley module 105.

[0052] The battery pack and trolley module may each include a common power hookup interface configured to be removably connected to a mating interface on the vehicle. FIG. 8 is a schematic rear view illustration of trolley module 105. As shown in FIG. 8, trolley module 105 may include a connection interface 800 configured to operatively connect the electronics and electrical power of trolley module 105 to thevehicle. Both trolley module 105 and the interchangeable battery pack (not shown) may include the same connection interface for connecting to the vehicle for compatibility.

[0053] Also, as shown in FIG. 8, trolley module 105 may include structural brackets 805 which a loading mechanism of the vehicle is configured to use for lifting and mounting trolley module 105 to the vehicle. The battery pack (not shown) includes the same structural brackets, also for compatibility.

[0054] FIG. 9 is a schematic left side view illustration of trolley module 105.

[0055] FIG. 10 is a schematic right side view illustration of trolley module 105.

[0056] In some embodiments, the trolley module may include a cooling module configured to keep temperatures of the components of the trolley module down. For example, in some embodiments, the trolley module may include a plurality of fans on one or more sides / surfaces of the trolley module.

[0057] FIG. 11 is a schematic top view illustration of the trolley module. As shown in FIG. 11 , trolley module 105 includes a cooling module 1100. In this case, cooling module 1100 includes a plurality of fans atop trolley module 105.

[0058] FIG. 12 is a schematic bottom view illustration of trolley module 105.

[0059] FIG. 13 is a schematic system diagram of the electrical system of the vehicle with a battery pack attached to the vehicle. As shown in FIG. 13, an electrical system 1300 may include a battery pack 1305, which may include a first (top) battery 1310 and a second (bottom) battery 1315. As illustrated, battery pack 1305, when installed / mounted on the vehicle is operatively connected to a vehicle control system 1320. Data may be communicated between battery pack 1305 and vehicle control system 1320, such as state of charge (SOC), current, voltage, limits, temperature, etc.

[0060] For comparison, FIG. 14 is a schematic system diagram of the electrical system of the vehicle with the trolley module attached. As shown in FIG. 14, a system 1400 includes trolley module 105. Trolley module 105 includes a virtual top battery 1405 and an actual bottom battery 1410. Trolley module 105 further includes a trolley supply unit controller 1415. Trolley supply unit controller 1415 communicates with vehicle control system 1320. For example, data is exchanged between trolley supplyunit controller 1415 and vehicle control system, such as state of charge, current, voltage, limits, temperature, etc.

[0061] Virtual top battery 1405 is a component that receives power via the trolley system adapter. Due to the processing of trolley supply unit controller 1415, virtual top battery 1405 is seen by vehicle control system 1320 as a large or infinite supply battery. That is, trolley module 105 includes trolley supply unit controller 1415 configured to modulate electrical power received from a trolley system via the trolley module, wherein trolley supply unit controller 1415 is configured to deliver power to the vehicle (via vehicle control system 1320) in a manner that is indecipherable, by the vehicle, from power delivered to the vehicle by the battery pack. In other words, when the trolley module 105 is mounted to vehicle 100, the power it provides to the vehicle is essentially identical to the power a battery would provide (e.g., similar voltage range, similar current range, etc.). In that sense, the vehicle 100 does not distinguish between the power received from a battery and the power received from the trolley module 105.

[0062] FIG. 15 is a schematic system diagram of a trolley supply unit controller of the trolley module. As discussed above, trolley supply unit controller 1415 communicates with vehicle control system 1320. As shown in FIG. 15, trolley supply unit controller 1415 includes various computing and communications hardware, such as servers, circuitry, displays, etc. Further, controller 1415 includes a device processor 1500 and a non-transitory computer readable medium 1505 including instructions executable by device processor 1500 to perform the processes discussed herein.

[0063] The non-transitory computer readable medium may include any suitable computer readable medium, such as a memory, e.g., RAM, ROM, flash memory, or any other type of memory known in the art. In some embodiments, the non- transitory computer readable medium may include, for example, an electronic storage device, a magnetic storage device, an optical storage device, an electromagnetic storage device, a semiconductor storage device, or any suitable combination of such devices. More specific examples of the non-transitory computer readable medium may include a portable computer diskette, a floppy disk, a hard disk, a read-only memory(ROM), a random access memory (RAM), a static random access memory (SRAM), a portable compact disc read-only memory (CD-ROM), an erasable programmable readonly memory (EPROM or Flash memory), a digital versatile disk (DVD), a memory stick, and any suitable combination of these exemplary media. A non-transitory computer readable medium, as used herein, is not to be construed as being transitory signals, such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through a waveguide or other transmission media (e.g., light pulses passing through a fiber-optic cable), or electrical signals transmitted through a wire.

[0064] Instructions stored on the non-transitory computer readable medium for carrying out operations of the present embodiments may be instruction-set- architecture (ISA) instructions, assembler instructions, machine instructions, machine dependent instructions, microcode, firmware instructions, configuration data for integrated circuitry, state-setting data, or source code or object code written in any of one or more programming languages, including an object oriented programming language such as Smalltalk, C++, or suitable language, and procedural programming languages, such as the "C" programming language or similar programming languages.

[0065] Aspects of the present disclosure are described in association with figures illustrating flowcharts and / or block diagrams of methods, apparatus (systems), and computing products. It will be understood that each block of the flowcharts and / or block diagrams can be implemented by computer readable instructions. The flowcharts and block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of various disclosed embodiments. Accordingly, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions. In some implementations, the functions set forth in the figures and claims may occur in an alternative order than listed and / or illustrated.

[0066] Trolley supply unit controller 1415 may include networking hardware configured to interface with other nodes of a network, such as a LAN, WLAN, or other networks. Further, controller 1415 may be configured to receive data from a plurality ofsources and communicate information to one or more external destinations. Accordingly, controller 1415 may include a receiver 1510 and a transmitter 1515. (It will be appreciated that, in some embodiments, the receiver and transmitter may be combined in a transceiver.)

[0067] Any suitable communication platforms and / or protocols may be utilized for communication between controller 1415 and other components of the system. Since the various sources of information may each have their own platform and / or protocol, the system may be configured to interface with each platform and / or protocol to receive the data.

[0068] In some embodiments, computer readable medium 1505 of controller 1415 includes instructions, executable by processor 1500, for modulating electrical power received from a trolley system via the trolley module and delivering power to the vehicle in a manner such that the power delivered by the trolley module to the vehicle appears to the vehicle as a large or infinite supply battery.

[0069] In addition, the computer readable medium further includes instructions for delivering power to the vehicle from a combination of the trolley system adapter and the battery of the trolley module in order to maintain the battery of the trolley module at a predetermined state of charge. For example, the system may be configured to maintain the battery of the trolley module at 80% charge.

[0070] It will also be noted that the predetermined charge level can also change depending on the machine task. For instance, if the vehicle is, during a given work shift, tasked with starting to haul from a different mining level, this predetermined charge level can be changed to suit this task better. For instance, if the new task location is at the end of a longer ramp that has no trolley, the battery could be kept at a SOC of 60% so that the vehicle can use regenerative braking while going down the ramp and charge the battery during this drive.

[0071] Further, the computer readable medium further includes instructions for delivering power to the vehicle from a combination of the trolley system adapter and the battery of the trolley module such that extra power is utilized during high loadconditions by partially depleting the battery of the trolley module temporarily. For example, if the vehicle is required to drive up an incline (particularly when loaded), additional power may be required. Therefore, under such conditions, the system may tap further into the power stored in the battery of the trolley module. Once the high load condition has passed, the system may restore the standard charge of the battery (e.g., 80%).

[0072] It will be understood that the trolley module enables a vehicle with little to no modifications to operate in either an existing overhead catenary system (OCS) or a new environment in which on-board power (e.g., a battery pack) will be employed. The system enables the machine to pick up a trolley module as needed to swap energy sources as necessitated by the operating conditions. This provides needed flexibility for the vehicle fleet or mine operator to ensure the system is forward and backward compatible.

[0073] It will also be appreciated that the vehicle may include an auxiliary battery, which may power the vehicle during power unit swapping procedures and / or for propulsion over short distances for various purposes.

[0074] While various embodiments have been described, the description is intended to be exemplary, rather than limiting, and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Although many possible combinations of features are shown in the accompanying figures and discussed in this detailed description, many other combinations of the disclosed features are possible. Any feature of any embodiment may be used in combination with, or substituted for, any other feature or element in any other embodiment unless specifically restricted. Therefore, it will be understood that any of the features shown and / or discussed in the present disclosure may be implemented together in any suitable combination. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.

Claims

CLAIMSWe claim:1 . A trolley module for an electric vehicle, comprising: a battery; a trolley system adapter; and a trolley supply unit controller configured to modulate electrical power received from a trolley system via the trolley module, wherein the trolley supply unit controller is configured to, in a first mode of operation, deliver power collected via the trolley system adapter to the vehicle to propel the vehicle and, in a second mode of operation, deliver power directly from the battery to propel the vehicle beyond catenary lines of a trolley system.

2. The trolley module of claim 1 , wherein the trolley supply unit controller includes: a device processor; and a non-transitory computer readable medium having instructions stored thereon for performing the following steps: modulating electrical power received from the trolley system via the trolley module; and delivering power to the vehicle in a manner such that the power delivered by the trolley module to the vehicle appears to the vehicle as a large or infinite supply battery.

3. The trolley module of claim 1 or 2, wherein the trolley system adapter and the battery of the trolley module are connected in parallel.

4. The trolley module of any one of claims 1 to 3, wherein the trolley module is interchangeable with a battery pack.

5. The trolley module of any one of claims 1 to 4, wherein the trolley module further includes a cooling module.

6. An electric vehicle, comprising: a drive system configured to operate on electrical power; a receptacle configured to receive a replaceable power unit; a trolley module that is configured to be removably mounted in the receptacle of the vehicle and adapted to power the drive system of the vehicle; wherein the trolley module includes a trolley supply unit controller configured to modulate electrical power received from a trolley system via the trolley module.

7. The electric vehicle of claim 6, wherein the trolley supply unit controller is configured to deliver power to the vehicle in a manner that is indecipherable, by the vehicle, from power delivered to the vehicle by a separate battery pack that is interchangeable with the trolley module.

8. The electric vehicle of claim 6, wherein trolley supply unit controller is configured such that the power delivered by the trolley module to the vehicle appears to the vehicle as a large or infinite supply battery.

9. The electric vehicle of any one of claim 6 to 8, wherein the trolley module includes a trolley system adapter and a battery; and wherein the trolley system adapter and the battery of the trolley module are connected in parallel.

10. The electric vehicle of any one of claim 6 to 9, wherein the trolley module further includes a cooling module.11 . The electric vehicle of claim 9, wherein the trolley supply unit controller includes: a device processor; and a non-transitory computer readable medium having instructions stored thereon for modulating electrical power received from a trolley system via the trolley module.

12. The electric vehicle of claim 11 , wherein the computer readable medium further includes instructions for delivering power to the vehicle from a combination of the trolley system adapter and the battery of the trolley module in order to maintain the battery of the trolley module at a predetermined state of charge.

13. The electric vehicle of claim 11 , wherein the computer readable medium further includes instructions for delivering power to the vehicle from a combination of the trolley system adapter and the battery of the trolley module such that extra power is utilized during high load conditions by partially depleting the battery of the trolley module temporarily.

14. A system for supplying energy to an electric vehicle comprising: a battery pack configured to be removably mounted on an electric vehicle and adapted to power a drive system of the electric vehicle; a trolley module configured to be removably mounted on the vehicle and adapted to receive power from a trolley system and use it to power the drive system of the electric vehicle; wherein the trolley module is interchangeable with the battery pack; wherein the trolley module includes a trolley supply unit controller configured to modulate electrical power received from the trolley system via the trolley module, and wherein the trolley supply unit controller is configured to deliver power to the electric vehicle in a manner that is indecipherable, by the electric vehicle, from power delivered to the electric vehicle by the battery pack.1915. The system of claim 14, wherein the battery pack includes a first battery and a second battery; and wherein the trolley module includes a trolley system adapter and a battery.

16. The system of claim 15, wherein the trolley system adapter and the battery of the trolley module are connected in parallel.

17. The system of any one of claims 14 to 16, wherein trolley supply unit controller is configured such that the power delivered by the trolley module to the vehicle appears to the vehicle as a large or infinite supply battery.

18. The system of any one of claims 14 to 17, wherein the trolley module further includes a cooling module.

19. The system of any one of claims 14 to 18, wherein the battery pack and trolley module each include a common power hookup interface configured to be removably connected to a mating interface on the electric vehicle.

20. The system of any one of claims 14 to 19, wherein the battery pack and the trolley module each have substantially the same form factor.

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