Systems and methods for an electric-powered vacuum excavator

Abstract

A vacuum system configured to vacuum spoils at an excavation site, comprising a vacuum tube, at least one pump, a power system comprising at least one power source, at least one electric motor, and a controller operatively coupled to the power system, the at least one electric motor, and the at least one pump, and programmed to provide control signals. The at least one power source is configured to operate in first and second modes, the at least one electric motor is configured to operate in a first direction in correspondence with the first mode and in a second direction in correspondence with the second mode, and the at least one pump pressurizes the vacuum system when the at least one electric motor is operated in the reverse direction.

Description

31681-789 (3252WO01)SYSTEMS AND METHODS FOR AN ELECTRIC- POWERED VACUUM EXCAVATORCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 703,563, filed October 4, 2024, which is incorporated herein by reference in its entirety.DISCUSSION OF ART

[0002] The field of the disclosure relates generally to excavation machines, and more particularly, to power systems and blowers of vacuum excavation machines, as well as mechanical arrangements (e.g., belt assemblies) and separation systems (e.g., storage tanks) for vacuum excavation machines.

[0003] With the increased use of underground utilities (e.g.. underground utility pipes, such as water and gas pipes and underground utility lines (e.g., power lines and telecommunications lines (e.g., coaxial, fiber))), it has become more important to locate and verity' the placement of buried utilities before installation of additional underground utilities or before other excavation or digging work is performed. Conventional digging and excavation systems, such as shovels, post hole diggers, powered excavators, and backhoes may be limited in their use in locating buried utilities as they may tend to cut, break, or otherwise damage utility' pipes and other utility lines during use.

[0004] Devices have been previously developed to create holes in the ground to non-destructively expose underground utilities to view. One design uses high pressure air delivered through a tool to loosen soil and a vacuum system to vacuum away dirt after it is loosened to form a hole. Another system uses high pressure water delivered by a tool to soften the soil and create a soil / water slurry mixture. The tool is connected with a vacuum system for vacuuming the slurry' mixture away into a collection tank. The tank may then be emptied by opening a door on the tank.31681-789 (3252WO01)

[0005] Certain prior art (e.g., combustion-powered) vacuum excavators reverse the flow of air through the system (e.g.. dig tube and tank) via use of a four-way valve, and as such rely on other components (e.g., valves) to accomplish a reversible pump / blower system. Accordingly, there is a need for improved reversibility' of components in excavators.SUMMARY

[0006] In one aspect, a vacuum excavator system includes a vacuum system that includes a vacuum tube and at least one pump, the vacuum system configured to vacuum spoils at an excavation site. The vacuum excavator system also includes a power system including at least one power source, the at least one power source configured to provide power to at least the vacuum system. The vacuum excavator system further includes at least one electric motor. The vacuum excavator system yet further includes a controller operatively coupled to the power system, the at least one electric motor, and the at least one pump, the controller programmed to provide control signals to control (i) power components of the power system, (ii) the at least one electric motor, and (iii) the at least one pump. The at least one power source is configured to operate in a first mode and a second mode different than the first mode. The at least one electric motor is configured to operate in a first direction in correspondence with the first mode of the at least one power source and in a second direction in correspondence with the second mode of the at least one power source. The at least one pump pressurizes the vacuum system when the at least one electric motor is operated in the reverse direction.

[0007] In another aspect, the at least one power source is a hybrid power source including an internal combustion engine and an electric power source. In yet another aspect, the at least one power source includes an electric power source.

[0008] Various refinements exist of the features noted in relation to the above-mentioned aspects of the present disclosure. Further features may also be incorporated in the above-mentioned aspects of the present disclosure as well. These refinements and additional features may exist individually or in any combination. For31681-789 (3252WO01) instance, various features discussed below in relation to any of the illustrated embodiments of the present disclosure may be incorporated into any of the abovedescribed aspects of the present disclosure, alone or in any combination.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The following drawings form part of the present specification, and are included to further demonstrate certain aspects of the present disclosure. The disclosure may be better understood by reference to one or more of these drawings in combination with the detailed description of specific embodiments presented herein.

[0010] FIG. 1 is a side view of a vacuum excavator system according to one embodiment of the present disclosure.

[0011] FIG. 2 is a rear perspective view of the vacuum excavator system of FIG. 1.

[0012] FIG. 3A is a front perspective view of a hybrid vacuum excavator system according to one embodiment of the present disclosure.

[0013] FIG. 3B is a diagram of a control system of the hybrid vacuum excavator system of FIG. 3 A.

[0014] FIG. 4 is a front perspective view of components of the hybrid vacuum excavator system of FIGS. 3 A and 3B.

[0015] FIG. 5 is an alternate front perspective view of the hybrid vacuum excavator system of FIGS. 3 A and 3B, with a boom of the hybrid vacuum excavator in an extended position.

[0016] FIG. 6 is a rear view of the hybrid vacuum excavator system of FIGS. 3A and 3B.

[0017] FIG. 7 is a front perspective view of an electric vacuum excavator system according to one embodiment of the present disclosure.31681-789 (3252WO01)

[0018] FIG. 8 is a front perspective view of components of the electric vacuum excavator system of FIG. 7.

[0019] FIG. 9A is a schematic view7of various embodiments of the vacuum excavator system.

[0020] FIG. 9B is a detail schematic view7of part of the vacuum excavator system of FIG. 9A.

[0021] FIG. 9C is a partial schematic view of various embodiments of the vacuum excavator system.

[0022] FIG. 9D is a schematic view7of a control system of various embodiments of the vacuum excavator system.

[0023] FIG. 10 is a top perspective view7of an alternative mounting of various embodiments of the vacuum excavator system.

[0024] FIG. 11 is a flow7diagram of a process for using electric motors of various embodiments of the vacuum excavator system to control components in a reversible manner.

[0025] Corresponding reference characters indicate corresponding parts throughout the several views of the drawings. Although specific features of various examples may be shown in some drawings and not in others, this is for convenience only. Any feature of any drawing may be referenced or claimed in combination with any feature of any other drawing.DETAILED DESCRIPTION

[0026] The present disclosure relates to a vacuum excavation system and method for at least in part electrically pow ering a vacuum excavator. By pow ering the vacuum excavator at least in part by electricity, benefits such as a reversible blower and reduced noise may be realized. A reversible blower for a vacuum excavator eliminates the need for a valve (e.g., a four-w ay valve) to reverse air flow in the vacuum excavator system, and enables pressurization of the system, which assists with31681-789 (3252WO01) offloading and / or unplugging components of a tube assembly of the vacuum excavator, where the tube assembly may include components such as a flexible portion and have various fittings and connections to facilitate excavation, such as a first extension and second extension, described herein. Additional benefits and advantages are described below.

[0027] More specifically, the present disclosure relates to a vacuum excavator system for a vacuum excavator. The vacuum excavator system may utilize an electric power source (e.g., a battery7system including one or more batteries, where the battery system may be provided on-board, and / or off-board (e.g., on the ground via a separate trailer), and / or an off-board power source (e.g., electric power grid power) or an electric generator set), or a combination of off-board and on-board power sources) to power various components of the vacuum excavator. Such components may include, but are not limited to, various pumps and other accessories. The vacuum excavator may be configured as (i) a hybrid vacuum excavator that utilizes a combination of an engine (e.g., an internal combustion engine) and the electric power source (e.g., battery' and / or other electric power source) to power the various pumps and other components, or (ii) an electric-only vacuum excavator that utilizes the electric power source (e.g., battery and / or other electric power source) to power the various pumps and other components.

[0028] When introducing elements of various embodiments disclosed herein, the articles “a”, “an”, “the”, and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including”, and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

[0029] Unless otherwise indicated, approximating language, such as “generally”, “substantially”, and “about”, as used herein indicates that the term so modified may apply to only an approximate degree, as would be recognized by one of ordinary7skill in the art, rather than to an absolute or perfect degree. Accordingly, a value modified by a term or terms, such as “about”, “approximately”, and “substantially” is not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument31681-789 (3252WO01) for measuring the value. Additionally, unless otherwise indicated, the terms “first”, “second”, etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to, for example, a “second” item does not require or preclude the existence of, for example, a “first” or lower-numbered item or a “third” or higher- numbered item. The term “fluid” as used herein may include liquid (e.g., water), air, and / or other gasses including but not limited to compressed gasses such as nitrogen, CO2, and the like, depending on the context.

[0030] FIG. 1 is a side view of one embodiment of a vacuum excavator system 100 for a vacuum excavator according to one embodiment of the present disclosure. Vacuum excavator system 100 includes a front portion 102, a rear portion 104, and a longitudinal axis 106 that extends through front portion 102 and rear portion 104. Vacuum excavator system 100 is generally used for earth excavation at an excavation site and includes a fluid (e.g.. water) reservoir tank 108 and a spoils collection tank 110 (collectively also referred to as storage tanks (e.g., fluid storage tanks)), each of which may include one or more tanks, such as a pair of tanks. Water reservoir tank 108 may contain water to be used for excavation, and spoils collection tank 110 (also referred to as a spoils tank) may include the water that was used for excavation. This used water may have been vacuumed into spoils collection tank 110 after being used for excavating, as described below in more detail.

[0031] Vacuum excavator system 100 includes components for earth excavation, including an earth removal system 112. In one embodiment, earth removal system 112 includes a variety of components and / or systems (e.g., sub-systems), including (i) high-pressure w ater system 113 (also shown in FIGS. 2, 5, 7) including: (a) a water reservoir tank 108, (b) a high pressure pump (e g., pump 158, shown in FIG. 2. also referred to as a water pump), and (c) a wand 114 fed by a high-pressure water hose 116 (e.g. , hose 11 ) for directing pressurized water from wand 114 tow ard earthen material to cut the earthen material with the pressurized w ater from w and 114, and (ii) a vacuum system 118 including: (a) a boom 120 capable of supporting and extending a tube assembly 122A (also referred to as tube 122A or vacuum tube 122A) to certain lengths from on or around rear portion 104, where tube assembly 122 A (supported by31681-789 (3252WO01) the boom 120) has structural properties (e.g., diameter, material thickness) sufficient to vacuum large amounts of water and debris resulting from the cutting, and includes a flexible portion 122B and may have various fittings and connections to facilitate excavation, such as first extension 122C and second extension 122D; (b) a vacuum pump 124 for creating an air stream within vacuum system 118; and (c) a system for separating the spoils from the air stream, and / or other components, for example, additional optional systems, such as a drive system 126 (also referred to as boom drive system) for providing mobility7to boom 120, where mobility includes but is not limited to rotation, extension / retraction, and raising / lowering of the boom 120. While various components and systems (e.g., systems 113, 118) are grouped as being part of earth removal system 112. these components and systems may also be utilized separate from earth removal system 112. In other embodiments, boom 120 may be located at aportion of vacuum excavator system 100 other than rear portion 104, such as on or around front portion 102, or on or around other portions including but not limited to a portion between front portion 102 and rear portion 104.

[0032] Vacuum system 118 removes spoil material from the excavation site. Spoil material or simply ‘‘spoils’' may include, without limitation, rocks, cut earthen material (e.g., small particulate, such as sand to larger pieces of earth that are cut loose by the jet of high pressure water), slurry, and water used for excavation. The spoil material may have a consistency similar to water, a slurry, or even solid earth, organic material, or rocks. The terms used herein for materials that may be processed by the vacuum excavation system, such as. for example, “spoils,” “spoil material,” “cut earthen material,” “waste water,” “waste fluid,” “waste liquid,” and “water,” should not be considered in a limiting sense unless stated otherwise. Vacuum system 118 acts to entrain the cut earth and the water used to excavate the site in a stream of air. System 100 also includes vacuum pump 124 (also referred to as a blower in certain usages) which creates an airstream through tube 122 A to entrain the material in the airstream. Collection tank 1 10 removes at least a portion of cut earthen material and water from the airstream. Air exits one or more collection tank air outlets 128 through one or more conduits 130. Air is discharged through an exhaust 132 (shown in FIG. 2) from vacuum pump 124 after material is removed from the airstream. One or31681-789 (3252WO01) more filters 134 may assist in filtering air. In some embodiments, vacuum pump 124 may be a positive displacement pump. Such positive displacement pumps may include dual-lobe or tri-lobe impellers (e.g., a screw rotor) that draw air into a vacuum side of the pump and forces air out the pressure side. Vacuum pump 124 may be powered by an engine, electric motor, or a combination of an engine and electric motor, having a power output of, for example, at least 75 horsepower (hp), at least 100 hp, or at least 166 hp, more than 500 hp, or even only a few hp. As such, these hp’s are only example hp’s, and using hp’s ranging from only a few hp to over 500 hp or more is envisioned by the present disclosure, depending on a variety of factors such as the intended application / usage, etc. Alternative configurations of the vacuum excavator system 100 may be configured for dry vacuum excavation where no water is used for the excavation process. Such a dry vacuum excavator may utilize pressurized air (instead of water) to loosen spoil material, and has a wand, hose, air tank, and pump (similar to wand 114 and the high-pressure water system described above). For example, pressurized air may flow through the wand to perform cutting, and the spoils cut and vacuumed by a dry vacuum excavator may be dry spoils.

[0033] As shown in FIG. 1, vacuum excavator system 100 includes boom 120. However, boom 120 is optional, and alternative configurations may not have a boom. For example, in configurations without a boom, tube 122 A may still be utilized, except tube 122A will need to be manually manipulated by the operator to direct the vacuum suction toward the excavation site. When a boom (e g., boom 120) is present as part of the excavator, it is capable of rotating toward the excavation site to remove material from the excavation site, and tube assembly 122A may be manipulated to extend downward to the ground to vacuum spoil material from the excavation site. More specifically, flexible portion 122B, first extension 122C, and / or second extension 122D of tube assembly 122A may be manipulated by an operator to direct the vacuum suction toward the excavation site, where an open end of second extension 122D may provide for vacuuming material into and through tube 122A (or outputting pressurized air as in other embodiments described herein).

[0034] Vacuum excavator system 100 includes a power system 136 that may include an engine (e.g., an internal combustion engine), batteries (e.g., an31681-789 (3252WO01) electric system), or a combination of an engine and batteries (e.g., a hybrid system), as described in more detail below in connection with other embodiments. Power system 136 may deliver power to boom drive system 126 (e g., a mechanical, hydraulic, or electric transmission system) to manipulate the boom position and to earth removal system 112. Additional aspects of power system 136 are described in more detail below, and the connections of the various components of system 100 are illustrated schematically in FIG. 9A.

[0035] A hydraulic system may be present on system 100 for controlling certain features. The hydraulic system may include various hydraulic cylinders, for example for dumping (such as a tank dumping cylinder (e.g., collection tank 110)), and / or for boom drive system 126 which may contain hydraulic actuators such as linear actuator 127 A, as well as a motor 127B for manipulation of the boom (e.g., boom 120) for handling a dig tube (e.g., tube 122A). A hydraulic pump 170 of the hydraulic system may be electric powered and / or powered by rotation of an engine (e.g., engine 166). For example, hydraulic cylinders (not shown), used to tilt collection tank 110, may be powered by a hydraulic pump (e.g., hydraulic pump 170, shown in FIGS. 3 A and 4) provided for this purpose, where pump 170 may be powered by power system 136, which may include an engine (e.g., engine 166. shown in FIG. 3A, such as an internal combustion engine), or an electric motor (e.g., electric motor 168, shown in FIGS. 3A, 4, and 6-8, also referred to as an electric drive motor), or a combination of an engine and an electric motor. The hydraulic pump (e.g., hydraulic pump 170, shown in FIG. 3 A) connects to a hydraulic reservoir (not shown) and is driven by power system 136. A high-pressure output line and a return line connect the hydraulic pump (e.g., hydraulic pump 170, shown in FIG. 3 A) to the hydraulic cylinders (output and return lines not shown). Such a hydraulic cylinder is one example of an actuator of system 100. Actuators may be hydraulic or electric, and linear or rotary, described in more detail below. In some embodiments, a water pump such as pump 158 may be hydraulic powered instead of powered by an engine or an electric motor (e g., electric motor 1 8). In some configurations the hydraulic system may be eliminated by using electric actuators for all the functions served by hydraulics. For example, as should be understood, a linear actuator is an actuator that creates motion in a straight line, which31681-789 (3252WO01) may be referred to as the actuation dimension. Examples of linear actuators include, but are not limited to, mechanical actuators (such as screws, rack and pinion devices, belt drives, hydraulic cylinders, and pneumatic actuators), electro-mechanical actuators, and linear motors. Thus, while hydraulic cylinders are used in certain examples described herein, it should be understood that this is for example purposes only and that other actuators (e.g.. linear and non-linear actuators) may be used to drive one or more components (e.g., linkage assemblies) as discussed herein.

[0036] In the embodiment shown in FIG. 1 (as well as in the embodiments shown in FIGS. 2, 3 A, 3B, and 4-8). vacuum excavator system 100 includes a chassis 138 of a trailer 140, systems (e.g., systems 113, 118) and components thereof (e.g., components 108, 110, 114, 116) and other components of vacuum excavator system 100 may be mounted on chassis 138 so that chassis 138 supports the various systems and components of vacuum excavator system 100. For example, as shown in FIG. 1. tube 122 A may extend from rear portion 104 toward wand 1 14, and an operator may grip wand 114 to perform the cutting to form a hole 142 at the excavation site. In other embodiments, a vacuum excavator system may be configured as a motor vehicle-mounted vacuum excavator system (shown in FIG. 10), where the motor vehicle may also be considered part of the overall vacuum excavator system.

[0037] One or more example vacuum excavation systems may be utilized with or encompassed by the systems and methods disclosed herein. Examples of the one or more example vacuum excavation systems are disclosed in the U.S. patent application Ser. No. 16 / 630,057, entitled “Hydro Excavation Vacuum Apparatus Having Deceleration Vessels and Methods for Hydro Excavating a Site,” filed Jan. 10, 2020, the entire disclosure of which is incorporated by reference herein for all purposes.

[0038] FIG. 2 illustrates additional aspects of vacuum excavator system 100, in particular (i) additional filter components including one or more cyclones and a chamber of vacuum excavator system 100, (ii) a battery system of vacuum excavator system 100, and (iii) additional aspects of collection tank 110 and wand 114 of vacuum excavator system 100.31681-789 (3252WO01)

[0039] Air that exits one or more collection tank air outlets 128 through one or more conduits 130 in the manner described above is introduced into one or more cyclones 144 via one of conduits 130 to remove additional spoil material (e.g., water, small solids, such as sand, low density particles (e.g., sticks and grass, and the like)) not separated in collection tank 110. Material that collects in the bottom of cyclones 144 is collected in chamber 146, where cyclones 144 and / or chamber 146 is / are capable of being emptied or cleaned periodically or as needed.

[0040] Collection tank 110 has a generally cylindrical body 148 having a closed front end (e.g., closed front end 172, shown in FIG. 3A) and an openable rear end 150. A discharge door 152 is operatively connected to openable rear end 150 of tank body 148 by a hinge 154 that allows door 152 to swing open, thereby providing access to the interior of collection tank 110 for material discharge and cleaning. Hydraulic components, such as a pair of hydraulic cylinders (not shown, described above) may be provided for tilting the closed front end (e.g., closed front end 172, shown in FIG. 3 A) of collection tank 110 upwards in order to cause the contents contained therein to run towards discharge door 152 (alternatively, electric actuators could be used to provide the tilting). Discharge door 152 includes a gate valve and drain 156 which drains the liquid portion of the contents (e.g., slurry) in collection tank 110 without requiring door 152 to be opened. The gate valve (e.g., of gate valve and drain 156) may also be used to introduce air into collection tank 110 to reduce the vacuum in collection tank 110 so that door 152 may be more easily opened.

[0041] Additional details of wand 114 are provided below. Wand 114 is connected to an excavation fluid (e.g., water) pump 158 that supplies water to wand 114 via high-pressure water hose 116 (these components may be referred to as a cutting system). Pump 158 may supply a pressure of, for example, at least about 500 psi or at least about 1.000 psi (e.g., from about 1.000 psi to about 5,000 psi or from 1.000 psi to about 3,000 psi) to supply pressurized water to wand 114 via high-pressure water hose 116. In some embodiments, wand 114 includes a nozzle 160 such as a rotary7nozzle for controlling and directing water toward the earthen material to cut the earthen material. Pump 158 may be connected directly or indirectly to high-pressure water hose 116 (e.g.. there may be intermediate hosing / couplings (not shown) connecting high-pressure31681-789 (3252WO01) water hose 116 to pump 158). Generally, any rotary nozzle that causes the water to be directed toward the earthen material in a circular path at the site of the excavation may be used. Such rotary nozzles may include a rotor insert (not shown) with blades (not shown) that rotate around a longitudinal axis of the nozzle when water is forced through the nozzle. The rotor insert may include three or more channels (not shown) that force fluid to flow in different pathways through the rotor insert to cause the water to move along a circular path as it contacts the excavation material (e.g., the water moves within a cone that extends from the nozzle toward the excavated material). In other embodiments, a straight tip nozzle that directs fluid along a straight path in a concentrated jet may be used as nozzle 160. High-pressure water hose 116 is connected via a valve (not shown) to excavation fluid pump 158 to provide water to the earth removal system 112 as selected by the user. As system 100 is used to dig a hole 142 (shown in FIG. 1), a distal end of w and 114 is aimed and pressed downw ardly tow ard the ground. For larger diameter holes, wand 114 may be moved in a generally circular manner as it is aimed and pressed downward, thereby loosening material from a large cross-section area. Slurry formed in the hole is vacuumed through an open end of second extension 122D of tube 122A and accumulates in collection tank 110. Once the excavation is completed and the utility7(e.g., pipe, line, etc.) that was previously surrounded by the (excavated) material is exposed, vacuum system 118 may be shut down, and the operator(s) may examine or repair the utility (e.g., pipe, line, etc.) as needed. Further aspects of wand 114 and the pressurized water used in the cutting system are described below7and shown in FIGS. 9A and 9B.

[0042] In operation, the airstream having water and cut earth entrained therein is pulled through tube 122A and through one or more (e.g., a series) of conduits (e.g., conduits 130) and is pulled into collection tank 110. Vacuum pump 124 generates vacuum in the system to pull water and cut earthen material into system 100 for processing. Collection tank 110 removes at least a portion of cut earthen material and water from the airstream. Air exits one or more collection tank air outlets 128 through one or more conduits 130 and is introduced into cyclones 144 via conduit(s) 130 to remove additional spoil material (e.g., water, small solids, such as sand, low density particles (e.g., sticks and grass, and the like)) not separated in the collection tank.31681-789 (3252WO01)Material that collects in the bottom of cyclones 144 is collected in chamber 146. In alternative embodiments, material collected in the chamber 146 is conveyed by a cyclone discharge pump (e g., peristaltic pump) or, alternatively, is gravity fed to a dewatering system (none of which are shown).

[0043] The air removed from cyclones 144 may be introduced into one or more filter elements (e.g., filter elements 134) before entering vacuum pump 124. Vacuum pump 124 may be disposed in or near a compartment of power system 136. Air is removed from the system 100 through (vacuum) exhaust 132.

[0044] Any plurality of components of system 100 that are capable of being driven by an electric motor and / or that would benefit from being driven by an electric motor may be driven by an electric motor. Moreover, such electric motors maybe battery- -powered, or powered by the electric power grid and / or an electric generator. For example, because electric motors are more easily reversed in their operation direction (e.g., in comparison to combustion engines), electric motors have expanded functionality in certain systems, such as system 100 that have a plurality of components that may benefit from being individually driven by a dedicated electric motor. As described below in more detail, electric motors allow, for example, for the vacuum pump 124 to be reversed more easily (representing just one benefit of electric motors) and without the need for air flow valves that reverse air flow (e.g., 4-way valves) and / or the additional need of hydraulic components in configurations where the vacuum pump 124 is hydraulically driven. As such, a plurality of electric motors may be used in system 100 to drive a plurality of components, individually and / or collectively. For example, in a hybrid configuration of system 100 (described below in more detail), the engine is disengaged (e.g., by a clutch) from the vacuum pump drive system (described below) and only an electric motor is used (e.g., for reverse operation of pump 124).

[0045] Vacuum excavator system 100 may be used to dig multiple holes (e.g., hole 142) before having to empty collection tank 110. Once collection tank 110 is full, it may be emptied at an appropriate site, such as a dump site. Once door 1 2 is opened, dumping of the contents (e.g.. slurry) from collection tank 110 may take place as described above. For this purpose, tank collection 110 may be pivotally31681-789 (3252WO01) atached to chassis 138 at a pair of hinges (not shown) that pivot about a horizontal axis transverse to axis 106 to allow collection tank 110 to pivot as the hydraulic cylinders move the forward end of collection tank 1 10 up and down, and such that when the hydraulic cylinders push the forward end (e.g., forward end 172, shown in FIG. 3A) of collection tank 110 upward, liquid and solid mater retained in collection tank 110 may be discharged through openable rear end 150 of collection tank 110 (e.g., when door 152 of openable rear end 150 is open).

[0046] Optionally, running the length of the interior of collection tank 110 may be a nozzle tube (not shown) that includes nozzles for directing high pressure water about the interior of collection tank 110, and particularly towards the base of collection tank 110. Such nozzles are actuated by opening a valve (not shown) connected to a (e.g., water) pump (e.g., pump 158), which delivers high pressure water from the pump to the nozzles for producing a vigorous cleaning action in collection tank 110. When the nozzles are not being used for cleaning, a small amount of water may be allowed to continuously drip through the nozzles to pressurize them so as to prevent dirt and slurry from entering and clogging the nozzles.

[0047] Regardless of the configuration of power system 136 (e.g.. hybrid or electric-only), vacuum pump 124 may be directly driven (e g., via power transfer without mechanical overload protection devices, such as clutches and / or belts) or indirectly driven (e.g., via power transfer with mechanical overload protection devices, such as clutches and / or belts) by power from power system 136. When vacuum pump 124 is reversed, such that it pressurizes components of vacuum system 118, air from the vacuum pump 124 enters through exhaust portion 132.

[0048] As described below in more detail, various configurations of power system 136 exist. For example, a batery system 162 (shown in FIGS. 3A, 4, 6, 7, and 8) which includes one or more bateries may be used in connection with hybrid and electric embodiments of vacuum excavator system 100. Power system 136 may also be configured to utilize power from the power grid and / or generator, and the power may be converted and / or otherwise conditioned for compatibility with components of system 100 (e g., AC power may be converted and conditioned to provide suitable DC31681-789 (3252WO01) power). Power system may be configured to utilize each of battery power, power grid power, and / or generator power, and in any combination thereof. Vacuum pump 124 may be driven entirely by an electric motor, such as an electric motor 168 (shown in FIG. 3A), which may be present in an entirely electric configuration of power system 136, as shown in FIGS. 7 and 8, or in a hybrid configuration of power system 136, as shown in FIGS. 3 A, 3B, and 4-6. In the hybrid configuration, electric motor 168 is actively providing power to vacuum pump 124 and an engine (e.g., engine 166) may not be actively providing power. Alternatively, vacuum pump 124 may be powered entirely by (a) an internal combustion engine (e.g., engine 166, a configuration of a power system 136), or (b) a combination of an electric motor (e.g., electric motor 168) and engine (e.g.. engine 166 in the hybrid configuration of power system 136). A hydraulic pump (e.g., hydraulic pump 170 shown in FIG. 3 A) and / or excavation fluid pump (e.g., pump 158) may be powered in the same manner as outlined above for vacuum pump 124. In one embodiment. DC motors may be implemented for the motors. In another embodiment, AC motors may be implemented for the motors. In yet further embodiments, a mixture of DC and / or AC motors may be implemented. Accordingly, a power source may be determined and set on a per-component basis, using any combination of electric-based and / or combustion-based power.Hybrid Vacuum Excavator.

[0049] FIG. 3 A illustrates a front perspective view of a hybrid vacuum excavator system 100 A, which has the same base components (e.g., components 108, 110, 114, 116) and systems (e.g., 112, 118, 126) as vacuum excavator system 100, but is configured such that power system 136 is a hybrid power system 164, which includes an engine 166 and one or more electric motors 168. FIG. 3A also illustrates a hydraulic pump 170 and a closed end 172 of collection tank 110 of vacuum excavator system 100A.

[0050] FIG. 3B illustrates a control system 174 for hybrid vacuum excavator system 100A. Control system 174 includes controls 176 and a controller 178. Controls 176 are in operative communication (e.g.. wired, wireless, or a combination of wired / wireless communication) with controller 178. Controller 178 controls a31681-789 (3252WO01) plurality of components of system 100A via a plurality of control signals. For example, controller 178 controls at least boom 120 (in configurations that include a boom (which is optional)) via control signal 180, battery system 162 (in configurations having the (optional) batten system) via control signal 182, electric motor 168 via control signal 184, engine 166 via control signal 186, hydraulic pump 170 via control signal 188, excavation fluid pump 158 via control signal 190, and vacuum pump 124 via control signal 192. Controller 178 controls the speed and power of electric motor(s) 168. For example, in certain configurations or conditions electric motor 1 8 powering vacuum pump 124 may be commanded to run at a specific speed, a specific power, and / or commanded to maintain a specified vacuum setting or pressure setting within vacuum system 118. Additionally, electric motor 168 may enable high fluid flow and deep vacuum (e.g., 27 inches Hg) capabilities (described in more detail below). Yet further, a motor controller, such as a variable frequency drive (VFD, not show n) or an inverter (not shown), may be part of a motor control system of electric motors 168. Control system 174 may also control any clutches (e.g.. on the engine 166 and / or electric motors 168), other pumps, and similar components of system 100A that are capable of being controlled by a controller. One or more operator controls (not shown) of controls 176 may be in data communication with controller 178. Operator controls 176 may include, for example, a remote control and / or machine mounted controls comprised of levers, switches, dials, buttons, or any other appropriate controls, whether now existing or later developed. In some embodiments, at least one of controls 176 is not in direct physical communication with controller 178, and instead communicates with controller 178 wirelessly, such as through one or more of near-field (e.g., Bluetooth, Bluetooth Low Energy, LoRA. Near Field Communication (“NFC”), Wi-Fi, Wi-Max, etc.), radio (e.g.. RF), or cellular communication technology (e.g., 3G, 4G, 5G, LTE, etc ). This also applies to any other devices that are connected for communication with controller 178. Hybrid vacuum excavator system 100A may be provided with one or more vacuum settings such that one or more vacuum modes (e.g., strengths) may be selected through operator controls of controls 176. Controller 178 may be configured to set the vacuum strength, thus providing for adapting to different site conditions and vacuuming needs.31681-789 (3252WO01)

[0051] Further description of hybrid power system 164 and the corresponding power transfer system is disclosed below. In the embodiment of a hybrid vacuum excavator system 100A as shown in FIGS. 3 A, 3B, and 4-6, hybrid power system 164 is configured such that a portion of the power to operate vacuum excavator system 100A is provided by electric drive motor 168 and the other portion of the power is provided by (e.g., internal combustion) engine 166 (e.g., gas or diesel). For example, hybrid power system 164 may utilize a 48-volt (e.g., Lithium Ion) battery system 162 capable of a certain amount of amps (e.g., 600 amps) for electric power. The power for the electric portion of hybrid power system 164 is supplied by battery' system 162 which is utilized to store electric power on-board vacuum excavator system 100A (e.g., self- contained electrical power, as opposed to connection with grid power or an outside power source). Alternatively, (optional) battery system 162 may be configured as an off-board system (e.g., having its o n trailer utilized in connection with (e.g., alongside) trailer 140 of system 100 A). Yet further, electric power may be supplied by connecting on-board systems (e.g., drive systems) to the power grid and / or generator power. When power system 136 is configured as hybrid power system 164, the power system 136 may include a plurality of power components 193 to provide the necessary and / or desired power characteristics and levels for system 100A. For example, the power components 193 of hybrid power system 164 may include power inverters, converters (e.g., AC to DC converter, DC to AC converter, DC to DC converter, AC to AC converter, etc.), power conditioners, and any other electrical and / or electronic components (e.g., capacitors, rectifiers (e.g., diodes), inductors, transformers (e.g., step- up, step-down), relays, coils, fuses) for transforming, conditioning, and / or transmitting power for use in system 100 A. For example, power conditioning may include selecting and / or configuring power components 193 to smooth out voltage fluctuations such as spikes, transients, and electrical noise. Power components 193 may be operatively coupled with controller 178 so that controller 178 can control power components 193 and power components 193 can provide operational information to controller 178 (for example, power components 193 may include the ability to transmit operating parameters and / or diagnostic data to controller 178 so that controller 178 is able to determine a state or condition of power components 193). In the case of connecting system 100A to AC power (e g., grid or generator power), the AC grid or generator31681-789 (3252WO01) power may be converted to usable DC power to charge one or more batteries of (optional) battery system 162 by on-board conversion circuitry (not shown), which may be part of hybrid power system 164. Additionally, system 100A may have on-board male and / or female electrical plugs / receptacles for 120 V, 60 Hz power, which may be used to plug system 100A into an external power source, such as grid power, to charge one or more batteries of (optional) battery system 162, or provide other power throughout system 100A (e.g., if battery system 162 is not utilized). System 100A may have its systems (e.g., system 164) configured for any variety of other standard power grid voltage and / or frequency (e.g., 277 V / 480 V three phase, 220-240 V, 50 Hz, etc.) depending on the intended (e.g., geographical) usage. While the aspects of such power components are described in connection with system 100A. such aspects apply equally to system 100 (and system 100B, shown in FIGS. 7 and 8). System 100A may also include an on-board temperature control system 195 (described in more detail herein) that is operatively coupled to and controlled by controller 178.

[0052] In the illustrated configurations shown in FIGS 3A, 3B, and 4- 6, if battery7system 162 is utilized, it may be selectively connected to at least one electric drive motor 168 and controller 178, for driving components, such as fluid excavation pump 158, hydraulic pump 170, and vacuum pump 124. Alternatively, each of fluid excavation pump 158, hydraulic pump 170, and / or vacuum pump 124 may have its own dedicated electric motor 168. In some configurations, for service work (e.g., diagnostics) or normal vacuum excavation operations, hybrid vacuum excavator system 100A may be operated entirely by the electric portion of hybrid power system 164, which includes electric drive motor 168 and may include (optional) battery system 162. In some configurations, for service work (e.g., diagnostics) or normal vacuum excavation operations, vacuum excavator system 100A may be operated entirely by (e.g., internal combustion) engine 166. Operating on solely one of the electric system (e.g., battery system 162. or grid / generator) or engine 166 may be beneficial for particular service and / or diagnostic work. For example, operating the hydraulic system (e.g., hydraulic pump 170 for raising or lowering the collection tank 110 and / or fluid excavation pump 158 (e.g., for running the high pressure water of the cutting system)) may be accomplished without the need to start engine 166 by utilizing battery system31681-789 (3252WO01)162 to power electric motor 168 for providing (e.g., mechanical) power to fluid excavation pump 158 of the cutting system and / or hydraulic pump 170. Engine 166 and electric drive motor 168 are each connected to controller 178. The schematically illustrated controller 178 may be physically provided as a single controller or as a plurality of segregated controllers of an overall control system. For example, there may be individual controllers for: main machine control (e.g., 12V), display control (e.g., 12V), and motor controllers for individual electric motors (e.g., 48V), and any other of a plurality of control scenarios.

[0053] FIG. 4 illustrates additional aspects of hybrid vacuum excavator system 100 A, including various drive shaft, belt, and clutch components of hybrid power system 164. Power (e.g., to vacuum pump 124) may be transferred from electric drive motor 168 and / or engine 166 by components of a drive system 200 which may include belts, pulleys, drive shafts, clutches, and the like associated with electric motor 168 and / or engine 166. For example, engine 166 selectively transfers power to an intermediate drive shaft 194 through engine clutch 196 and an engine belt drive assembly 198. Various types of clutches including centrifugal clutches and electric clutches may be used. In configurations where engine clutch 196 is a centrifugal clutch, engine 166 may not transfer power to drive shaft 194 until a threshold speed has been reached (e.g., the centrifugal clutch is selected and designed to engage and disengage at a certain rotational speed of the engine 166). Engine belt drive assembly 198 (e.g., including belt and sheaves) may transfer power from an output portion of engine clutch 196 to drive shaft 194, although other drive systems are contemplated and usable, such as driveshafts, gears, or direct connection. In some configurations engine clutch 196 may be omitted, whereby the output shaft of engine 166 is continuously connected to drive shaft 194. Intermediate drive shaft 194, engine clutch 196, and an engine belt drive assembly 198 may be part of a drive system 200. Various types of clutches including centrifugal clutches and electric clutches may be used. In configurations where engine clutch 196 is a centrifugal clutch, engine 166 may not transfer power to drive shaft 194 until a threshold speed has been reached (e.g., the centrifugal clutch is selected and designed to engage and disengage at a certain rotational speed of the engine 166). Engine belt drive assembly 198 may selectively transfer power to drive shaft 19431681-789 (3252WO01) through an additional belt drive assembly 201 (also referred to as a belt assembly) including belt and sheave components.

[0054] Alternatively, electric drive motor 168 may be directly connected to drive shaft 194. and a clutch (similar to engine clutch 196) may be positioned between an output shaft of electric drive motor 168 and drive shaft 194 for selectively transferring power from electric motor 168 to drive shaft 194. In certain embodiments, drive shaft 194 may be omitted from the drive system and electric drive motor 168 and engine 1 6 may selectively transfer power (through the utilization of clutches) to a drive shaft 202 of vacuum pump 124. A selectively engageable clutch, such as an electric clutch, may be utilized at any of hydraulic pump 170, fluid excavation pump 158, and / or vacuum pump 124, allowing for individual engagement or disengagement of the components with hybrid power system 164. For example, when a clutch is engaged, power may be transferred from hybrid power system 164 to the component through the corresponding drive system. When a clutch is disengaged, power is not transferred from hybrid power system 164 to the component.

[0055] Additionally, using vacuum pump 124 as an example of a pump that is being powered, power transmission to vacuum pump 124 may be stopped by: (1) disengaging a vacuum pump clutch assembly 204, or (2) discontinuing power to electric drive motor 168 and shutting off engine 166 or disengaging engine clutch 196. If system 100A is / are provided without engine 166 (e.g., such as in system 100B, shown in FIGS. 7 and 8), the power transmission to earth removal system 112 (including vacuum system 118) may be stopped simply by discontinuing power to a designated electric drive motor 168. Various other combinations of the aforementioned components can disengage, engage, and regulate the power transmission from the electric motor and / or the engine to the components.

[0056] Further, engine 166 may recharge (optional) battery system 162 whenever electric drive motor 168 is not needed for powering vacuum pump 124, and / or other pumps such as high pressure water pump (e.g., pump 158) and hydraulic pump (e.g.. pump 170), and / or other driven components. This may be accomplished with a clutch assembly in a disengaged state (e.g., assembly 204 is a clutch assembly31681-789 (3252WO01) on vacuum pump 124). The additional belt drive assembly 201, drive shaft 202, and vacuum pump clutch assembly 204 may also be part of drive system 200, such that drive system 200 may include intermediate drive shaft 194, engine clutch 196, an engine belt drive assembly 198, additional belt drive assembly 201, drive shaft 202, and / or vacuum pump clutch assembly 204.

[0057] An example, non-limiting operation of hybrid system 164 includes operating engine 166 and electric drive motor 168 in parallel. During operation of hybrid system 164, the electric system (e.g., including battery system 162, grid power, and / or generator power and one or more electric drive motors 168), or engine 166, or both, may provide power to components of vacuum excavator system 100A depending upon certain conditions. In a nonlimiting example, and for simplicity, assume in the following example that drive shafts of electric drive motor 168 and engine 166 are connected at a 1 : 1 speed ratio (such as by a belt drive) (e.g., if the engine drive shaft turns at 2500 rpm, then the electric drive motor drive shaft will turn at 2500 rpm). For conditions where vacuum excavator system 100A is preparing for vacuum excavation, or when a vacuum excavation operation is completed, or when no load / minimal load is present, a controller (e.g., controller 178 shown in FIG. 3B) will command engine 166 to operate at high idle (e.g.. 3800 rpm), while simultaneously, a motor drive shaft is turning at 3800 rpm because electric drive motor 168 is coupled to engine 166 at a 1 : 1 speed ratio, however the controller does not command electric drive motor 168 to begin powering until a motor engagement threshold speed has been reached (e.g., 3600 rpm). During this 'no load” condition (e.g., where electric drive motor 168 is being driven by engine 166) the control system implemented by the controller (e.g., controller 178) enables electric drive motor 168 to serve as a generator to charge (optional) battery system 162 (e.g., regeneration mode).

[0058] Further regarding charging, engine 166 may charge one or more batteries of (optional) battery system 162 during no load or low load conditions. For example, hybrid vacuum excavator system 100A may experience periods of time where minimal power is required, such as when low amounts of material are being vacuumed, and furthermore, vacuuming operations may start and stop a plurality of times to excavate the material as described further below, and during these times engine31681-789 (3252WO01)166 may charge one or more batteries of battery system 162. The charging of one or more batteries of battery system 162 may be limited to a certain rate, such as 200 amps. In some configurations, one or more batteries of battery system 162 is / are charged at this maximum rate. Alternatively, the charging rate of one or more batteries of battery system 162 is scaled based on a state of charge (SoC) of the battery / batteries of battery system 162 (e.g.. where the battery / batteries charge is / are averaged to a setpoint). This may prevent drawing too much power from engine 166 and prevent pulling high current when not necessary, to increase battery life. The end result is a SoC that oscillates around a value during vacuuming, charging more aggressively if the battery SoC dips too low (below a threshold), and backing off if the battery SoC is higher than a threshold. Generally, with this recharging system, the torque that electric motor 168 pulls for recharging is proportional to the distance the battery system 162 is from a desired / threshold level of recharge. This system may leave some buffer space in the battery SoC, for example, the buffer space in the battery SoC may be necessary' in a configuration where the vacuum excavator system (e.g.. system 100B, shown in FIGS. 7 and 8) is entirely powered by the one or more batteries, and no engine may be present.

[0059] When hybrid power system 164 of hybrid vacuum excavator system 100A begins to experience a load, such as when spoil material is introduced into tube 122A, the speed of electric drive motor 168 and engine 166 may begin to drop. When the speed of engine 1 6 and electric drive motor 168 hits a motor engagement threshold (e.g., 600 rpm), controller 178 may command electric drive motor 168 to cease charging (e.g., exit regeneration mode) and begin driving by pulling stored electricity from battery system 162 such that electric drive motor 168 and engine 166 are both contributing power to hybrid vacuum excavator system 100A, particularly vacuum pump 124. Other loads on hybrid system 164 may include activation of hydraulic pump 170 and / or activation of excavation fluid pump 158.

[0060] Additional benefits of electric power systems (e.g., battery system 162 and electric motor(s) 168) are described below. Regeneration may be utilized by incoming or outgoing spoils to recharge one or more batteries of battery system 162. For example, a turbine (e.g., turbine 208, shown in FIG. 9A) may be positioned in collection tank 1 10 near the incoming spoils inlet (e.g., waste fluid inlet,31681-789 (3252WO01) inlet where material from vacuum system 118 enters collection tank 110, shown in FIG. 9A (also see FIG. 9C)) where the incoming flow of spoils at the waste fluid inlet would turn the turbine (e.g., turbine 208, shown in FIG. 9A), generating electrical power to provide a charge to one or more batteries (e.g., of battery' system 162). An additional benefit of this system is deceleration of the spoils material, which provides for more effective separation of spoils from the air stream. Using an electric power system (e.g., battery system 162 and electric motor(s) 168) in conjunction with a power system that includes an (e.g., internal combustion) engine (e.g., engine 166) provides the ability to use a smaller (e.g., internal combustion) engine, which may be beneficial for a variety ofreasons (e.g., less fuel consumption, less noise, less weight). The hybrid system 100A may use hydraulic actuators as described herein, or may use electric actuators that w ould remove the need for a hydraulic system, or a mix of both types of actuators. In some embodiments, regenerative braking may be implemented, for example as an energy recovery mechanism. Regenerative braking may be particularly useful in electric or hybrid configurations of vacuum excavator system 100 that are mounted to a vehicle 1000 such as shown in FIG. 10 and as described herein. The kinetic energy resulting from braking of a vehicle associated with mounting and / or transporting of vacuum excavator system 100 may be converted into electrical energy (e.g., instead of waste heat) by reversing one or more electric motors such as electric motors 168, effectively turning such motors into generators. The generated electrical energy may then be stored in one or more batteries, such as batteries of battery system 162, which can then be later used to pow er any variety of battery' -pow ered components of vacuum excavator system 100. Additional benefits of regenerative braking may include reduced wear and tear (e.g., extending the lifespan of components such as brake pads and / or rotors).

[0061] FIG. 5 illustrates an alternate front perspective view of hybrid vacuum excavator system 100A. FIG. 6 is a rear view of hybrid vacuum excavator system 100A. As discussed above, in the hybrid excavator embodiment (e.g., FIGS. 3 A, 3B, and 4-6), components including but not limited to clutches, shifts, and pulleys may be used for controlling pow er transfer to and from components. As noted above, electric drive motor 168 may be connected to directly drive vacuum pump 124. In such31681-789 (3252WO01) a configuration of hybrid vacuum excavator system 100 A, the components of hybrid vacuum excavator system 100A, such as the excavation fluid pump (e.g., pump 158) and hydraulic pump (e.g., pump 170) may be powered by an additional electric drive motor (e.g., 168) or individual electric drive motors (e.g., plural electric drive motors 168). In configurations where electric drive motor 168 is directly connected (e.g., no overload protection device, such as a clutch or belt, between electric drive motor 168 and vacuum pump 124) to drive vacuum pump 124, electric drive motor 168 may be controlled by controller 178 based on a load sensed on vacuum pump 124. However, electric drive motor 168 may also be protected by dedicated overload controls within controller 178. Such overload controls may be provided to any / all of startup, stopping, and normal vacuum operations. For example, controller 178 may be programmed with a threshold torque limit (which may also be implemented as a threshold current limit, by way of the known relationship between current and torque) and / or to control and manage a startup torque. Power to electric drive motor 168 may be cutoff in the event that an input from a sensor to controller 178 indicates that the threshold torque limit is reached. Similar overload controls may be incorporated into the control of the electric drive motor(s) (e.g., electric drive motors 168) powering the excavation fluid pump (e.g., pump 158) and / or hydraulic pump (e.g., pump 170) such that the electric drive motor(s) (e g., electric drive motors 168), hydraulic pump (e g., pump 170), and / or fluid excavation pump (e.g., pump 158) are stopped upon controller 178 identifying the threshold current at the limit. Such a threshold used by controller 178 may prevent damage to the electric drive motor(s) (e.g., electric drive motors 168), drive components (e.g., components 196, 198, 201, 202, 204), hydraulic pump (e.g., pump 170), fluid excavation pump (e.g.. pump 158). vacuum pump (e.g., pump 124). and / or components (e.g., drive system 126) of the vacuum system 118 that may be operatively coupled to electric motor(s) 168. In the above-described alternative power configuration, each component may have its own electric drive motor, so that each component may benefit from individualized motor control in the manners described above. Some embodiments may be configured to predict component failure by way of measuring current draw, for example. By measuring current draw, predictions can be made as to potential issues such as bearing failures (e.g., blower bearing failures), as well as other component failures. For example, a detection of a high current at start-up or idle could sen e as an31681-789 (3252WO01) indication of component failure. Such monitoring for current draw may be performed by current monitoring circuitry implemented in conjunction with controller 178. for example. This may include the use of shunt resistors, current sense amplifiers, magnetic current sensors such as Hall effect sensors, MOSFETs with integrated current-sensing features, and other similar current sensing electrical / electronic components.

[0062] Another configuration of the hybrid vacuum excavator described herein includes a series hybrid configuration: A parallel hybrid configuration (e.g., an electric and engine hybrid configuration including an engine and electric motor that work together in parallel to power the drivetrain) has been disclosed in detail herein, however, a series hybrid configuration (e.g., an electric and engine hybrid configuration where an electric motor is the sole source of power for the drivetrain and the engine provides power for a generator to charge the battery and / or power an electric motor) could also be implemented, particularly in a configuration with electric vacuum excavator as disclosed below in other embodiments.Electric Vacuum Excavator.

[0063] FIG. 7 is a front perspective view of an electric vacuum excavator system 100B according to one embodiment of the present disclosure, where system 100B has the same base systems (e.g., 112, 118, 126) and components (e.g., components 108. 110, 114, 116) thereof as vacuum excavator system 100 / 100A, but power system 136 is configured as an electric only power system for powering one or more electric motors 168, for example. FIG. 8 is a front perspective detail view of components of the electric vacuum excavator system 100B of FIG. 7. Compared to the hybrid vacuum excavator system 100A which includes the hybrid power system 164 described above, in the electric vacuum excavator system 100B. the (e.g., internal combustion) engine (e.g., engine 166) may be entirely removed or otherwise present but inoperable. This results in electric vacuum excavator system 100B being electric powered only, with power system 136 being configured as electric power system 164A, as shown in the embodiment in FIGS. 7 and 8. Electric driven components may be incorporated into electric vacuum excavator system 100B utilizing electricity as the sole power source (e.g., from one or more batteries (e.g., of optional battery system31681-789 (3252WO01)162) and / or an external electric supply (e.g., grid power or generator power)). In the electric power system 164A configuration of system 100B, additional batteries may be provided as part of battery system 162 compared to the amount of batteries in the hybrid configuration. For example, compared to the hybrid power system 164 embodiment shown in FIG. 3A which may have a standard (e.g., single) battery system 162 configuration (e.g., since the hybrid configuration also uses engine 166 for power), electric power system 164A of vacuum excavator system 100B as show n in FIG. 7 has an expanded (e.g., double) battery system 162 configuration, which allows for more and / or larger batteries to meet the needs of the various electric actuators and electric motors (e.g., electric motor(s) 168) and / or other components to be powered via electric power) when battery system 162 is utilized (e.g.. instead of or in addition to grid and / or generator power). Additionally, while hybrid power system 164 may utilize a 48-volt Lithium Ion battery system 162 capable of 600 amps when battery system 162 is utilized, electric power system 164A of vacuum excavator system 100B may use greater than 48V Lithium Ion batteries and be capable of more than 600 amps when battery system 162 is utilized.

[0064] Additionally, or alternatively to using battery system 162, the electric power system 164A configuration of electric vacuum excavator system 100B may be powered by an external power source (which may be off-board batteries), the power grid, and / or a generator (e.g., power from a generator system), configured to meet the power requirements for the electric actuators and electric motors (e.g., electric motor(s) 168) of electric power system 164A and any other power requirements of system 100B. Such external power source may be used in combination with battery system 162, or in lieu of batten system 162. For example, power system 136 configured as electric power system 164A of system 100B may be configured to not use any batteries when system 100B is intended to be connected to an AC electric power source (e.g., grid or generator power) or, for example, if battery system 162 is malfunctioning or otherwise inoperable or intentionally not used for any other reason (e.g., extreme weather such as extreme heat or cold). To account for this configuration and operational option, electric power system 164A of system 100B may include power conversion and / or inversion electronics and the necessary wiring connections that enable the source31681-789 (3252WO01)AC power provided to system 100B to be converted to usable and stable DC power for the various components (e.g., pumps, such as pump 170, 158, etc.) of system 100B that may be DC-powered. For example, on a very hot day where batteries of battery system 162 may face an increased risk of (e.g., heat) damage if operated, battery system 162 may be disabled / bypassed, and instead the external AC power may be converted to the necessary DC power for running the various components of system 100B. System 100B may be also configured without any battery system 162 at all if it is known in advance that reliable AC power will be present at the site where excavation using system 100B will occur. Additionally, electric power system 164A of system 100B may be configured to have both usable AC power and usable DC power. For example, external AC power (e.g., grid or generator power) may on one hand be utilized onboard system 100B (e g., to power an AC outlet provided on system 100B, such AC outlet being usable to plug in other devices that use AC outlets for power), and on the other hand converted to DC power to power the DC-powered components of system 100B. Such an AC outlet provided onboard system 100B may alternatively be provided by inverting DC power from (optional) battery system 162 to provide onboard AC power (e.g., using power inversion electronics). While these additional power conversion / inversion and power delivery / distribution aspects are discussed in connection with system 100B, such techniques are likewise applicable to the electric power aspects of system 100 / 100A (including for hybrid power system 164).

[0065] An electric only configuration may also impact other functionalities of electric vacuum excavator system 100B. For example, the functionality of electric vacuum excavator system 100B may be carried out without the need for hydraulic power. It is common to use a hydraulically driven spoil tank dump actuator (e.g., to dump collection tank 110) due to the force required for raising and lowering the spoils tank (e.g., collection tank 110). However, the hydraulic system to drive the dump actuator may be the only hydraulic system on the vacuum excavator, which necessitates certain components and complexities (e g., hydraulic motor and supply of pressurized fluid, along with over-pressure detection and mitigation) that may otherwise be eliminated. By not using any hydraulic-driven actuator(s) for the dump actuator, raising and lowering of the spoils tank (e.g., collection tank 110) may be solely31681-789 (3252WO01) electric, e.g., an electric motor or electric actuator. An electric actuator may be powered by an electric power source (e.g.. off-board / extemal power supply or (optional) onboard battery’ system 162 and controlled by control system 174, including controller 178). Similarly, in this configuration, any other components that were hydraulically powered may be converted to be electrically actuated, such as any separation systems (e.g., additional separation systems (e.g., vibratory screens or similar) that may be used as part of electric vacuum excavator system 100B). In this regard, FIG. 7 shows that system 100B includes a dedicated electric motor 168 A for vacuum pump 124, in addition to electric motor 168. Any number of different electric motors 168 may be provided to independently power any number of components, based on design needs and / or preferences. For example, vacuum pump 124 that is critical for high-load vacuuming functions may be best served by having an independent motor driving it, to better handle the loads that the motor will be subject to.Vacuum pump startup and loading - monitoring slip / loading.

[0066] Electric motor torque is generally consistent through its speed range (from minimum rotation speeds to maximum rotation speeds). This presents opportunities for certain advantages of using electric drive motors (e.g., electric drive motors 168), such as the torque providing for a shorter time to get vacuum pump 124 up to vacuuming speed to create an air stream and desired amount of vacuum. For example, hybrid power system 164 in system 100A, or electric drive motor 168 of hybrid power system 164 alone, or an electric drive motor 168 of electric power system 164 A may be capable of powering vacuum pump 124 from zero rpm to vacuuming speed (thus, completing a start-up) in a certain amount of time (e.g., about 10 seconds), where a comparable sized traditional vacuum excavator having only an internal combustion engine may take a longer amount of time (e.g., about 30 seconds). However, the applicable drive system (e.g.. drive system 200) must be capable of transferring the power. In some embodiments the motor torque from electric drive motor 168 is limited to less than its full capability’ by controller 178 to prevent drive line issues, such as belt slip. In some configurations, the belt slip may be monitored by controller 178 by comparing the rotational speed of electric drive motor 168 and the rotational speed of drive shaft 202 of vacuum pump 124 to calculate the amount of belt31681-789 (3252WO01) slip (e.g.. as a percentage difference from transmission without any slip). Controller 178 may take into account a known "no slip’7speed ratio defined between electric drive motor 168 and drive shaft 202 of vacuum pump 124 (e.g., from a pulley size ratio between drive and driven pulleys). Then, controller 178 may control the output of electric drive motor 168 to keep the belt slip within a predefined range during a startup (e.g., 50% or less. 40% or less, 30% or less, 20% or less. 15% or less, 10% or less). Controller 178, with fast response and processing times, may initially identity 100% slip at the very onset of starting electric drive motor 168 since vacuum pump 124 will not respond with instantaneous rotation. This special case notwithstanding, slip is monitored by controller 178 and actively managed to not exceed the threshold slip value while applying maximum allowable amps (e.g.. torque) to electric drive motor 168 in order to increase the speed of vacuum pump 124 as quickly as possible, with the goal being to minimize the time to get the vacuum excavator system 100 / 100A / 100B up to vacuuming conditions while remaining within a loading threshold on the drive system. In other configurations, the slip is monitored by controller 178 to not exceed the threshold slip value while running speed control of electric drive motor 168 rather than torque control (e.g., running at maximum allowable speed of electric drive motor 168, within the constraint of the slip threshold, in order to get vacuum pump 124 to a vacuuming speed as quickly as possible). Further yet, electric drive motor 168 may be controlled to pulse ON / OFF a plurality of times (e.g., without actively controlling torque or speed in relation to belt slip) to effect a smooth startup of vacuum pump 124. In some configurations, a startup routine may be adapted from Vermeer's U.S. Patent Application Publication No. 2023 / 0149942, the entire contents of which are incorporated by reference herein. Active belt slip management by controlling electric drive motor 168 may be particularly advantageous in an alternative configuration in which there is no clutch (e.g., clutch mechanism 204 is not present), to enable selective connection and disconnection between electric drive motor 168 and vacuum pump 124.

[0067] Although particularly useful during startup of vacuum pump 124 to the vacuuming speed, belt slip monitoring may be useful in other scenarios as well. For example, belt slip monitoring may take place during normal vacuum operations, either continuously or periodically. During the course of performing the31681-789 (3252WO01) normal vacuum operations, there may be a certain amount of belt slip that is normal or expected in a fully functional, as-new vacuum excavator system 100 / 100A / 100B. A belt slip threshold during vacuum operation may be the same as or different from the belt slip threshold during a startup (e.g., belt slip threshold during vacuum operations may be 50% or less, 40% or less, 30% or less, 20% or less, 15% or less, 10% or less). The expected or allowable amount of belt slip may be programmed to controller 178 or learned by controller 178 when vacuum excavator system 100 / 100A / 100B is put into service. As vacuum excavator system 100 / 100A / 100B experiences wear from prolonged use, the amount of belt slip will increase, and controller 178 will observe and identify the increased amount of belt slip. Increased belt slip may also be identified due to a component failure, unexpected event, etc. When controller 178 identifies an excessive amount of belt slip, based on exceeding a stored threshold or an abrupt change for example, it may trigger an alert and / or change the operational status of vacuum excavator system 100 / 100A / 100B (e.g.. prevent or alter vacuum operations with the vacuum pump 124). Controller 178 may also issue predictive warnings as the calculated belt slip amount gradually approaches the stored belt slip limit threshold.

[0068] As will be apparent to one of ordinary skill in the art, a belt drive assembly (e.g.. belt assembly 201) may include a flexible belt wrapped partially around at least a driving pulley and a driven pulley, sometimes referred to as sheaves. Example belt drives are shown between intermediate drive shaft 194 and each of engine 166 and electric drive motor 168, and also between intermediate drive shaft 194 and vacuum pump drive shaft 202. Belt slip may be monitored for an individual or compound belt drive. The belt is selectively engageable with the driving and driven pulleys to transfer rotational power. A tensioner and / or a clutch may optionally be provided. When engaged and transferring pow er, speeds of the driving and driven pulleys may be monitored, by tracking with respective sensors and reporting signals to controller 178. In some configurations, belt slip is determined by a speed comparison between the prime mover element (e.g., electric drive motor 168) and the ultimate driven element (e.g., earth removal system 112). In other configurations, one or more intermediate components may be used in monitoring belt slip. As noted above, a known “no slip” speed ratio may be factored into the belt slip equation by controller 178. A31681-789 (3252WO01) slip percentage (SP) may be calculated as follows: SP = 100 * (driving RPM - driven RPM) / driving RPM. However, where a known speed ratio exists between the driving component and the driven component (such as through the use of different size pulleys for a belt drive, or gearboxes, etc. that are present in the drive system between the drive and driven shafts), the ratio must be taken into consideration, therefore the calculation for slip percentage would be: SP = 100 * (driving RPM - driven RPM * drive ratio) / driving RPM. Two separate examples are given below, both resulting in 10% belt slip: (a) in a 1 : 1 drive ratio system: SP = 100 * (1000 RPM - 900 RPM *1) / 1000RPM = 10%; (b) in a 2:1 drive ratio system: SP = 100 * (1000 RPM - (450 RPM * 2) / 1000RPM = 10%.

[0069] Electric motors for driving the vacuum pump 124 may provide additional benefits. For example, so called “deep vacuuming” (e.g., when vacuuming large amounts of water, or heavy and / or dense spoils where much of the air stream is replaced by spoils or liquid) represents a substantial power drain for conventional vacuum excavators (powered by an internal combustion engine) due to different loading characteristics an internal combustion engine compared to an electric motor due to the sudden and / or sustained high load in deep-vacuum conditions. For example, the electric motor may have the capability to intermittently operate at a torque that exceeds the rating for continuous operation which may be utilized to power the blower for a period of time when deep-vacuum capabilities are needed for certain conditions. Deep vacuuming conditions may exist for about 20 seconds, or less than one minute, or less than two minutes. Deep-vacuuming capabilities would be increased via use of an electric motor on vacuum excavator systems 100 / 100A / 100B, allowing for improved performance by providing long length deep-vacuum conditions and / or a quicker response to deep-vacuum conditions. High torque reduces delay, but may provide such instantaneous power that it may have a potential negative impact on components, such as belts (e.g.. belts may bum up due to the high torque). As such, control systems may be needed to restrict any high torque applications from reaching levels that may harm belts. For example, the controller (e.g., controller 178) may be programmed to recognize situations when it may be necessary' to limit high torque (similar to the belt slip thresholds described above). This may be accomplished in association with various31681-789 (3252WO01) sensors to provide the controller (e.g., controller 178) withnecessary data. For example, a temperature sensor may be placed adjacent to belts to detect abnormally high temperatures of the belts, where the controller may shut down the vacuum excavator and / or reduce high torque if a certain threshold temperature of the belts is sensed. Visual sensors may also be utilized to detect physical degradation of belt due to harmful temperatures. Any sensor useful in detecting the necessary conditions is envisioned.

[0070] System 100 / 100A / 100B may use closed loop control, e.g., PID control. For example, controller 178 may command electric motor 168 to ramp up speed until it encounters a slip threshold, at which point controller 178 maintains the motor speed until slip is reduced, or reduce the motor acceleration rate until slip is reduced. There may be a time delay between taking slip samples, such as 100 milliseconds.

[0071] Alternative to a belt drive (e.g., belt assembly 201), or in combination with a belt drive, some drive system configurations (e.g., such as for drive system 200) may utilize alternative overload protection devices, such as a clutch (e.g., clutch 196). The clutch may be electric, hydraulic, or other friction clutches that are capable of engagement and disengagement of a power source to a driven component. Additionally, the clutch may have a variable engagement, meaning the clutch may transfer power between the driving component and the driven component at a variable rate and may have at least one partially engaged state. Additionally, the clutch, although engaged, may slip during certain load conditions, leading to a difference in the driven shaft speed compared to the drive shaft speed (e.g., of a drive shaft such as drive shafts 194, 202). Such clutches may be monitored for slip by comparing the speed of a driven rotating component (e.g., drive shafts 194, 202, clutch output, etc.) to the speed of a driving rotating component (e.g., engine 166, electric drive motor 168, intermediate drive shaft 202, clutch input, etc.). Thus, the above details of belt slip calculations may be adapted or generalized to other driving and driven components as would be understood by one of ordinary skill in the art, without fully repeating the entire disclosure. Similar to the belt assembly (e.g., belt assembly 201) described above, electric drive motor 168 may be controlled to limit slip to a desired slip threshold, such that the above described features of belt slip monitoring may be more generally applicable to slip monitoring. Where a clutch is present in the drive line, controller 17831681-789 (3252WO01) may selectively operate the clutch (e.g., changing state or engagement condition between disengaged and engaged) in conjunction with active control of electric drive motor 168, or in lieu thereof.Alternative Modes (e.g., Economy Battery Charging Mode, Boost Mode).

[0072] One or more batteries of (optional) battery system 162 may be charged at a slower rate when engine 166 operates at a rate less than the high idle speed (e.g., less than 3600 rpm according to the prior example) during an alternative mode (e.g., economy charging mode). One or more batteries of battery system 162 may charge at any amperage above 0 amps. However, in the configuration described above (e.g., where engine 166 includes a centrifugal clutch), the recharging speed would be limited to the disengagement speed of the clutch, for example, above approximately 1500-2000 rpm due to the centrifugal clutch on engine 166 (the clutch would disengage below these speeds, therefore not providing power to charge one or more batteries of battery system 162). In configurations where no engine clutch is used, or an alternative clutch is used (such as an electric clutch), engine 166 may power electric drive motor 168 to charge the one or more batteries down to its lowest idle speed.

[0073] Battery7system 162 and electric drive motor 168 may also allow for a boost mode where vacuum excavator system 100 / 100 A / 100B, and specifically vacuum pump 124, is capable of higher performance for a short period of time. The maximum allowable current draw (e.g., battery discharge level) increases substantially (e.g., at least 100 percent, at least 120 percent, or at least 125 percent) for this limited period of boost time (e.g., 600 amp boost current, compared to 472 amp is 27 percent increase). The allowable boost time may be set by the manufacturer and / or derived from the battery specifications, and may be limited to a certain duration, such as 5 seconds, 10 seconds, or 20 seconds. Considerations are made to optimize power output in relation to the amount of current recharging of one or more batteries of battery system 162. Boost mode allows for higher performance over a short duration of time. Battery system 162 would beneficially allow for higher performance and / or longer duration boost modes. Boost mode may be used in the above-described deep vacuuming31681-789 (3252WO01) scenarios. For example, boost mode may permit the power system (e.g., batteries and motors) to increase torque rapidly and exceed the continuous rating for a defined period of time (e.g., between 20 seconds and less than two minutes) as described herein.Additional considerations for both hybrid and electric configurations.

[0074] For any configurations disclosed herein containing a batteiy system (e.g., battery system 162), in some conditions it may be necessary' to have heating and cooling systems for the one or more batteries. Some batteries are not capable of charging below zero degrees Celsius and / or may have limited discharge below zero degrees Celsius. Additionally, batteries may get too hot for safe or proper function (such as greater than approximately 45 degrees Celsius). When these conditions are expected, a heating or cooling system may be utilized to manage battery temperature. The on-board temperature control system 195 may be put into place to utilize on-board water or direct air exhaust (e.g., from exhaust 132) for providing cooling / heating, for example cooling / heating for battei ' system 162. The temperature control system 195 may be configured as a separate system having a supply of coolant, a pump, and a radiator. Sensors (e.g., temperature sensors) may be utilized as part of temperature control system 195 to sense temperatures and interface with controller 178 so that controller 178 may use data from the sensors to control the temperature control system 195 to keep one or more components, such as one or more batteries of battery system 162, within a desired temperature range.

[0075] More specifically, vacuum excavator system 100 / 100A / 100B may temperature control system 195, which may include an on-board coolant system (e.g., a heater / cooler system) for cooling / heating battery system 162. The coolant heater / cooler system may be powered by an external power source, such as a 120 volt plug (e.g., a same plug as used for over-night charging) for keeping battery system 162 warm in cold weather (or cold in warm weather). This is necessary' in some configurations where the battery will not charge below approximately 2 degrees Celsius, although it may still discharge below this temperature. During operation, heat created during discharge, such as vacuum operations, may' keep the battery warm31681-789 (3252WO01) enough to recharge during operation on cold days. In some configurations, the coolant heater / cooler system may even be powered by battery system 162. Battery system 162 itself may be utilized to provide power to the heater / cooler system, as well as reap the benefit from the warming (or cooling) coolant provided by the coolant heater / cooler system. The coolant may be water from tank 108 or a separate water supply that may be located on-board trailer 140 to provide cooling and / or heating for managing temperature of one or more components such as batteries of battery system 162 (or other components of system 100 / 100 A / 100B that may benefit from temperature control). Alternatively the coolant may be a refrigerant or other suitable industrial coolant. The coolant heater / cooler system may include tubing, piping, coils, fins, and / or other heat exchangers to convey coolant to / from components needing heating / cooling, and / or to sink or radiate heat. Having access to warmed or cooled coolant would increase utility and convenience, as warmed (or cooled) coolant may be utilized in a variety of scenarios including but not limited to the above-mentioned battery warming utility. For example, on very hot days cooled water may be utilized for cooling battery system 162 to prevent overheating and / or heat damage to the battery / batteries of battery system 162. To realize these heating / cooling capabilities, battery system 162 may be electrically tied into an existing coolant heater / cooler system provide on-board trailer 140 of vacuum excavator system 100 / 100 A / 100B. For example, fluid (e.g., water) used for excavation that is stored in one or more tanks such as reservoir tanks 108 may be heated. In some scenarios, the fluid may be heated in the tanks as the vacuum excavator system charges overnight. Heated fluid such as heated water may be useful to reduce the likelihood of freezing, and the heated water may also be beneficial in excavating hard, cold earthen material (such as during excavation in winter months) since the heated water may be better able to cut through the hard, cold earthen material.

[0076] As will be appreciated by those in the art, vacuum excavator system lOO / lOOA / lOOB, and variations thereof, may be configured for continuous-run vacuum excavation machines, such as vacuuming slurry from pits, and the like, or intermittent vacuum excavation machines, such as vacuuming material during a potholing operation. Continuous-run vacuum excavation machines may be designed to operate at or near 100 percent duty cycle and have a continuous, non-stop stream of31681-789 (3252WO01) material to vacuum. Such continuous-run machines may be electrically driven when components are sized according to the expected loading, and would typically be much larger than an intermittent vacuum excavator. Conversely, components may be sized smaller for a vacuum excavator configured for intermittent vacuum excavation operations, where the expected duty cycle of the vacuum excavator may be approximately 20 percent in some configurations, meaning that only about 20 percent of the time the vacuum pump is drawing full power from the power supply. This duty cycle is relative to a short portion of the day, for example, it may be continuously vacuuming at full power for 20 percent of a 100 minute period, or 20 percent of a 30 minute period, or about 20 percent of a 60 minute period. Battery system 162 (e.g., when on-board) may be sized such that the maximum is 20 percent of continuous vacuum operations during a period, such as a 150 minute period (e.g., 30 minutes of max. power vacuuming depletes battery system 162 from full charge). Normal interruption of vacuum operations renders the vacuum excavator configured for intermittent operation suitable for atypical workday, without requiring plug-in charging of batter}’ system 162. As noted above, the components of vacuum excavator system 100 / 100A / 100B may be sized and designed for intermittent and / or continuous vacuuming operations.

[0077] Referring to FIG. 3B, control system 174, including controls 176 and controller 178, would function in a near identical manner as described above for the hybrid configuration 100A when used with the electric embodiment (electric power system 100B shown in FIGS. 7 and 8) of system 100. except that signals such as signal 186 for engine 166 would not be required since the electric embodiment would not have engine 166. Additionally, power components 193 shown in FIG. 3B would serve the same function in electric power system 100B as in hybrid power system 100 A, except the power components 193 may be tailored for the particular electric power levels and characteristics of electric power system 100B. Likewise, on-board temperature system 195 shown in FIG. 3B would serve the same function in electric powder system 100B as in hybrid powder system 100 A. In one non-limiting example, controller 178 limits the current output of (optional) battery system 162 to a certain amount of amps, such as 522 amps, which may be a rated limit by the battery31681-789 (3252WO01) manufacturer. Battery system 162 may have a rated charge capacity, such as 261 amp hours (e.g.. the battery may run at 261 amps for an hour before recharge). There may be a safety factor included in the current limitations, however, the following sentences include some example values. The recharge rate in relation to the current of the battery / batteries of battery system 162 may be a certain amount of amps, such as 130 amps (which is related to a predicted estimation of the duly cycle, approximately 130 amps x 4 ~ 522 amps, so 20 percent operating time, 80 percent recharge time). Vacuum excavator system 100 / 100A / 100B may, for example, operate for half an hour without charging (e.g., 261 amp hours / 522 amp output). However, not all vacuum operations will require maximum amperage, so the duty cycle may be higher for lighter load conditions and may vary drastically depending on the characteristics of the vacuuming conditions. To fully charge the battery / batteries of battery system 162, it may be advisable for the customer to plug-in system 100 / 100A / 100B for charging between work shifts / days, however, it is not necessarily required to ensure operability. For charging, vacuum excavator system 100 / 100A / 100B may be plugged into a common 120 volt, 15 amp outlet.

[0078] Additionally, the current to drive electric motors (e.g., electric motors 168, 168A) may be artificially limited by control system 174 with respect to its maximum capability, for example in order to reserve cunent for operating the electric hydraulic pump and / or electric excavation fluid pump. In one example, the current to vacuum excavator electric drive motor 168 is limited to 472 amps to reserve 50 amps of current for operation of the electric hydraulic pump and / or electric excavation fluid pump (472 amps + 50 amps = 522 max. amps).

[0079] Control system 174 may be powered by a battery other than a battery of battery system 162. Referring to the hybrid configuration in system 100A, in the hybrid configuration, engine 166 may also have a separate battery (not shown) that is charged by an alternator of engine 166. Control system 174 and engine 166 may operate on a 12-volt system. However, in alternative configurations, such as the hybrid (system 100A) or the electric (system 100B) configurations, control system 174 may be powered by battery system 162. In this circumstance, the additional power consumption is also factored into the battery usage, but the current draw is minimal31681-789 (3252WO01) compared to the electric motors (e.g., electric motors 168, 168A) for vacuuming operations.

[0080] In general, an electric-only vacuum excavator (e.g., system 100B) as described herein may include a larger battery frame (e.g., box) (e.g., of battery system 162) compared to a hybrid vacuum excavator (e.g., system 100A) as described herein. For example, an electric vacuum excavator (e.g., system 100B) may include a two-box configuration for batteries (see FIG. 7 at 162) whereas a hybrid vacuum excavator (e.g., system 100A) may include a one-box configuration for batteries (see FIG. 3 A at 162). These are merely non-limiting examples, and the amount of batteries and dedicated battery space on each vacuum excavator configuration may be adjusted as needed. Weight and load distribution considerations may be also contemplated as part of the design process, based on the type of vacuum excavator (e.g., hybrid / electric) and / or its intended mode of transport (e.g., trailer- or non-trailer). With any of the power combinations listed above the vacuum excavation system 100 / 100 A / 100B may be on a pull-type unit (towed by a vehicle) or propelled by a prime mover (engine or electric motor) or integrated into a vehicle (e.g., vehicle 1000, shown in FIG. 10). Because batteries may add substantial w eight to the excavator, alternate battery storage / location configurations may be needed. For example, a separate generator set and / or battery system may be located on a separate trailer to avoid and / or offset the additional weight of the one or more batteries.

[0081] FIG. 9A is a schematic view of vacuum excavator system 100 / 100 A / 100B, as described above. Fluid from reservoir tank 108 is pumped through pump 158 to high-pressure water hose 116 for use by wand 114 in excavation. Pressurized w ater 206 exits from nozzle 160 of w and 114. Tube 122A is used to vacuum up the water / earth mixture, and, via the air stream created by the vacuum pump 124, spoils are carried to collection tank 110 (where a portion of the solid and / or liquid spoils are separated from the air stream), through one or more conduits 130, to filtering elements (including cyclones 144, chamber 146, and additional filters 134 - where additional solid and / or liquid spoils are separated from the air stream), before air enters vacuum pump 124. Air from the vacuum pump 124 is exhausted air out of exhaust 132. FIG. 9A also depicts collection tank 1 10 including an optional turbine 208. As31681-789 (3252WO01) discussed above, regeneration may be utilized by incoming or outgoing spoils to recharge one or more batteries of battery system 162 by a turbine (e.g.. turbine 208) positioned in collection tank 110 near the incoming spoils inlet (e.g., incoming material from dig tube 122A / boom conduit 130) where the incoming flow of spoils would turn turbine 208, providing a charge to the one or more batteries of battery system 162 when battery system 162 is present.

[0082] FIG. 9B is a detail view of part of vacuum excavator system 100 / 100 A / 100B, as described above. Specifically, FIG 9B is a detail view of the end of wand 114 with nozzle 160 that sprays water 206. As shown, pressurized water 206 exits from nozzle 160 of wand 114, to be aimed at the excavation site for excavation (see FIGS. 1 and 9A).

[0083] FIG. 9C is a partial schematic view of vacuum excavator system 100 / 100A / 100B, as described above. Specifically, FIG. 9C shows a reversible pump / blower configuration of vacuum excavator system 100 / 100A / 100B and air stream characteristics for each configuration. In one embodiment, a battery 214 (e.g., of battery system 162) is used to power electric motor(s) 168 / 168A. It should be understood that power for electric motor(s) 168 / 168A may alternatively or additionally be provided by the power grid or a generator, and such power grid / generator power (e.g., AC power) may be converted by power conversion electronics (e.g., of power components 193) to DC power, as described herein, so that electric motor(s) 168 / 168 A may be DC-powered and be operated in first or second direction to achieve pump / blower functionality. The first direction may be a forward direction, and the second direction may be a reverse direction opposite the forward direction, or vice versa. Alternatively, as described herein, in some embodiments electric motors 168 / 168 A may be AC motors and AC-to-AC conversion may be utilized to convert power from the power grid or a generator to that needed for powering the AC motors. As described above, when vacuum pump 124 is powered by (reversible) electric motor 168, vacuum pump 124 may also function in a reversible manner. For example, when the power source driving electric motors 168 / 168A is operated in a first mode (e.g., positive polarity, such as from battery system 162). electric motor 168 / 168A runs in a first direction, and pump 124 creates a vacuum air stream through conduit 130,31681-789 (3252WO01) collection tank 110, and tube 122A, such that the end of tube 122A (e.g.. the end of second extension 122D) has suction force to vacuum material up into collection tank 110, as shown by arrow(s) 210. On the other hand, when the power source driving electric motors 168 / 168A is operated in a second mode (e.g., negative polarity, such as from battery system 162), electric motors 168 / 168 A run in a second direction that is different (e.g., opposite) from the first direction, and pump 124 creates a pressurized air stream and provides a pushing (e.g., blowing) force through conduit 130, collection tank 110, and tube 122A, such that the end of tube 122A (e.g., end of second extension 122D) provides blowing force (e.g., air) outward, as shown by arrow(s) 212 (e.g., air from vacuum pump 124 may exit as exhaust from tube 122A, and exhaust 132 functions as an air inlet). Accordingly, tube 122A may effectively function in two modes by way of the reversibility of electric motor 168 / 168A, providing two opposite functions ((i) vacuum / suction in a first (e.g., forward) operation / rotation direction of electric motor 168, and (ii) high pressure (also referred to as pressurized) / blow in a second (e.g., reverse) operation / rotation direction of electric motor 168. each of which may be useful for excavation. For example, in suction mode, tube 122A may vacuum (e.g., suction up) waste fluid / slurry, whereas in high pressure mode pressurized air may (i) exit from tube 122A for use in clearing away (e.g., solid) material, (ii) have reverse flow to clear jammed material in tube 122A, and / or (iii) pressurize collection tank 110 and / or other parts of system 100 / 100A / 100B, to help with the evacuation (e.g., rapid evacuation) of fluid from system 100 / 100 A / 100B due to the pressurization. By reversing polarity (e.g., of the voltage provided from battery' system 162 that powers electric motor 168), control of the operation direction of components, such as vacuum pump 124 may be realized. One or more of a battery 214, which is / are part of the battery array of battery system 162, may power electric motor 168 / 168 A of vacuum pump 124. Battery system 162 may, in association with controller 178 (and / or other powder-control electronics of system 100 / 100A / 100B)) output power in positive and / or negative polarities. As illustrated by arrow 216 (positive polarity) and arrow 218 (negative polarity), battery system 162 may output different types of usable power for components, such as electric motor 168 / 168A (e.g., electric motor 168 for system 100A, electric motor 168A for system 100B), if such components (electric motor 168 / 1 8 A) are desired to be operated in at least two modes (e.g., the reverse operation aspects of pump 124 described herein).31681-789 (3252WO01)The relationship between the rotation (e.g., drive) direction of electric motor 168 / 168A relative to the positive and negative polarity driving direction / power is merely for illustration and is an example (e.g., the opposite of the relations shown in FIG. 9C may be utilized). Moreover, other electric motors (e.g., electric motors 168, 168A) of system 100 / 100 A / 100B may be configured to run / be driven in two different directions, as well, to provide the same duality for any other components (e.g., other pumps, etc.) of system 100 / 100A / 100B. In an alternative configuration, battery system 162 may only output one form of power, and each individual component, such as electric motor 168 / 168 A may include its own dedicated circuitry to enable electric motor 168 / 168A to operate in a reversible manner. For example, each DC-powered component of system 100 / 100A / 100B may be configured to convert positive power received from battery system 162 to negative power in order to reverse its operating direction. This may be performed in conjunction with controller 178 and / or a similar controller and / or other electronics that are part of system 100 / 100A / 100B. Any combination of configurations providing reversible power / operation is envisioned so long as the desired operability is obtained. While FIG. 9C refers to a battery 214 for providing the reversible configurations for pump 124, other power sources such as the power grid and / or a generator may be used to power electric motors 168 / 168A (e.g.. where the power from the power grid and / or generator may be converted from AC to DC for providing reversible DC power to electric motors 168 / 168A. If battery system 162 is not used, the above-described polarity functions would be in relation to grid or generator power. The air stream represented by arrows 210 and the air stream represented by arrows 212 would result from (reversible) operation of pump 124 regardless of if electric motors 168 / 168A are powered by battery (e.g.. battery 214) or other DC power source (e.g.. converted power from power gird and / or generator).

[0084] FIG. 9D is a schematic view illustrating additional aspects of control system 174 and the various components control system 174 controls. Control system 174 may include one or more processors that are operatively coupled to one or more memory devices. Such memory' devices may store one or more programs that provide program instructions and / or datafor carrying out various implementations (e.g., control) described herein, and may include volatile and nonvolatile memory and other31681-789 (3252WO01) ty pes of non-transitory data storage components. Volatile memory is memory that does not retain data values upon loss of power. Nonvolatile memory is memory that does retain data upon a loss of power. Examples of memory devices include random access memory (RAM), read-only memory7(ROM), hard disk drives, solid-state drives, universal serial bus (USB) flash drives, memory cards accessed via a memory card reader, floppy disks accessed via an associated floppy disk drive, optical discs accessed via an optical disc drive, magnetic tapes accessed via an appropriate tape drive, and / or other memory components, or a combination of any two or more of these memory components. In addition, examples of RAM include static random access memory (SRAM), dynamic random access memory (DRAM), magnetic random access memory (MRAM), and other such devices. Examples of ROM include a programmable readonly memory (PROM), an erasable programmable read-only memory (EPROM), an electrically erasable programmable read-only memory (EEPROM), or other like memory7device. Control programs and other software and hardware components associated with control system 174 may be upgradeable (e.g., via plug-in port such as USB or other data cable / connector standard, wired (e.g., local network), or wirelessly via an antenna and a data / communication wireless network (e.g., cellular, cloud)).

[0085] For example, each component controlled by or that is a part of control system 174 may include its own processor and memory. Controller 178 may include a processor (e.g., CPU) 220 and a memory' device 222 for storing and executing program instructions and / or data to perform control. Components 126, 124, 158, 162, 166, 168, and 170, for example, may also have their own dedicated processor and memory similar to controller 178. Vacuum pump 124 may include a processor 224 and a memory' device 226 for storing and executing program instructions specific to vacuum pump 124. Boom drive system 126 may include a processor 228 and a memory' device 230 for storing and executing program instructions specific to boom 120. Pump 158 may include a processor 232 and a memory' device 234 for storing and executing program instructions specific to pump 158. Battery’ system 1 2 may include a processor 236 and a memory' device 238 for storing and executing program instructions specific to battery system 162. Engine 166 may include a processor 240 and a memory device 242 for storing and executing program instructions specific to engine 166. Electric31681-789 (3252WO01) motor 168 may include a processor 244 and a memory device 246 for storing and executing program instructions specific to electric motor 168. Pump 170 may include a processor 248 and a memory device 250 for storing and executing program instructions specific to pump 170. Any singular processor and / or any singular memory device may instead be multiple processors and / or multiple memory devices, respectively. FIG. 9D also shows control signals 180, 182. 184, 186, 188. 190, and 192 (also shown in FIG. 3B) for controlling the various components (e.g., 120, 124... 170) via controller 178.

[0086] In one or more implementations, a control program of control system 174 (e.g., executed by controller 178) and programs for the various components 120, 124, 158, 162, 166, 168, and 170 is / are embodied in the form of source code that includes human-readable statements written in a programming language or machine code that contains numerical instructions recognizable by a suitable execution system, such as a processor or other system. Examples of executable programs include: (1) a compiled program that may be translated into machine code in a format that may be loaded into a random access portion of memory and run by a processor; (2) source code that may be expressed in proper format, such as object code that is capable of being loaded into a random access portion of memory and executed by a processor; and (3) source code that may be interpreted by another executable program to generate instructions in a random access portion of memory to be executed by a processor. Controller 178 may also control any clutches (e.g., clutch 196), and such clutches may have a processor and / or memory similar to those described above with respect to components 120, 124, 158, 162, 166, 168, and 170.

[0087] FIG 9A, 9B, 9C, and 9D are representative of and applicable to any of systems 100, 100A, and 100B (except, for example, with respect to components that are only present in certain embodiments, such as engine 166, which is not present in system 100B). For example, one or more of battery 214 may be present in any battery system 162 of systems 100, 100A, and / or 100B. The amount and type (e.g., voltage, size, capacity7, cold crank ability7, amperage) of battery7214 will vary7based on the needs of each system 100 / 100A / 100B, and may be selected in the manners disclosed herein. Moreover, while battery 214 is shown in FIG. 9C as powering electric motor 168 for pump 124, as described herein, one or more of battery 214 may power31681-789 (3252WO01) any number of electric motors 168 and / or 168A, which may in turn be individually or collectively coupled (e.g., wired) to operate the various components (e.g.. any pump, any actuator, and more generally any component capable of being powered by an electric motor) of systems 100 / 100 A / 100B. Battery 214 may be a 48V battery, or have any other voltage / amp rating sufficient to provide the power necessary for powering any components and / or (e.g.. sub-) system(s) of systems 100 / 100A / 100B. For example, battery 214 in electric system 100B may be of higher voltage / capacity than battery 214 in hybrid system 100 A.

[0088] It should be understood that while the components of vacuum excavator system 100 / 100 A / 100B described herein are illustrated as mounted on chassis 138 of trailer 140, these components may be towed or otherwise moved by a motorized vehicle, such as a car, truck, or skid steer, and may therefore include a tongue and / or hitch coupler to connect to the separate vehicle. It should be understood that the components of vacuum excavator system lOO / lOOA / lOOB may be either directly mounted to chassis 138 or indirectly mounted to chassis 138 through connections with other system components. As shown and described in connection with FIG. 10, in embodiments where vacuum excavator system 100 / 100A / 100B is mounted on a vehicle, vacuum excavator system 100 / 100A / 100B may be powered, in whole or in part, by a power source of the vehicle. The vehicle’s power source may be a battery, a hybrid system, a generator, and / or combinations thereof, and / or other similar power systems.

[0089] FIG 10 illustrates an alternative mounting embodiment for a vacuum excavator system 100 / 100A / 100B, where the components of vacuum excavator system 100 / 100 A / 100B are mounted on a vehicle (e.g., instead of a trailer (e.g., trailer 140) as shown in FIGS. 1-8). For example, components of vacuum excavator system 100 / 100 A / 100B may be mounted on self-propelled motor vehicle 1000 with a dedicated engine and / or motor (not shown) that propels the vehicle. In this embodiment, the components of vacuum excavator system 100 / 100A / 100B are supported by chassis 1002 and mounted on mounting bed 1004. Vehicle 1000 has a front portion 1006, a rear portion 1008, a longitudinal axis 1010, a cab 1012, tires 1014. and engine / motor compartment 101 . It should be understood that the components of vacuum excavator31681-789 (3252WO01) system 100 / 100A / 100B may be either directly mounted to chassis 1002 and / or mounting bed 1004 or indirectly mounted to chassis 1002 and / or mounting bed 1004 by way of various physical connections (e.g., mating fasteners, welds, etc.) present on or operable with chassis 1002 and / or mounting bed 1004. The function of system 100 / 100 A / 100B is otherwise the same as that described above for the trailer-mounted embodiment(s) shown in FIGS. 1-8.

[0090] FIG. 11 is a flow diagram illustrating a process 1100 for using an electric motor (e.g., such as electric motor 168 / 168A described above) to provide reversible operation of a component controlled by electric motor 168 / 168A. At step 1102, a desired operation state of a component is determined. For example, an operator may wish to clear a material jam in tube 122A by way of reversing the flow of vacuum pump 124 (both shown, e.g., in FIG. 1) to pressurize the component of vacuum system 118, in an attempt to clear tube 122A. At step 1104, the operator uses controls 176 (shown, e.g.. in FIG. 3B) to set a desired operation state of the component, such as vacuum pump 124. For example, reversible control of a pump, such as vacuum pump 124, may be by way of a switch of controls 176 that is located on a control panel of system 100 / 100A / 100B described above. The operator flips the switch to the desired state. There may be a plurality’ of control switches for various components of system 100 / 100A / 100B. At step 1106, controller 178 receives a signal from the switch and sends control signals to the necessary components (e.g., power systems 164 / 164A which may include (optional) battery system 162 (shown, e.g., in FIG. 3 A) or may instead use power grid and / or generator power as described herein), electric motor 168 (or 168A), and / or vacuum pump 124, and any associated power / drive components) and adjusts the operation state of the component. For example, this may include switching a polarity7of delivered power from battery' system 162, switching the drive direction of electric motor 168 / 168A, and switching vacuum pump 124 from a pump state to a blower state. At step 1108, the component that has had its state adjusted by controller 178 is operated in the adjusted state. For example, vacuum pump 124 is operated so that the air blown through tube 122A via vacuum pump 124 helps in dislodging a jam in tube 122 A.31681-789 (3252WO01)

[0091] The present disclosure relates to a vacuum excavation system and method for powering a vacuum excavator with electricity, including fully electric (e.g., battery only) or partially electric (e.g., hybrid) configurations. The technical effects that may be realized by the electric-powered feature in the practice of some embodiments of the described systems and techniques include: (a) the ability to realize usage of a reversible electric motor to power a vacuum pump on the vacuum excavator (compared to a non-reversible vacuum pump power source, such as an internal combustion engine, that requires a 4-way valve, as discussed above); (b) reduced noise; (c) the ability to use a smaller engine (e.g., in a hybrid powered machine) compared to conventional internal combustion engine-only excavators; (d) advantages provided by having access to high torque electric motor power (including expanded deep vacuuming capabilities, expanded ability’ to clear a clogged dig tube, expanded ability’ to unload an entire tank via a pressurized system); (e) expanded heating / cooling options (e.g., expanded ability to heat / cool fluid, such as coolant, for better managing temperature(s) of on-board components including one or more batteries); (1) increased scalability (e.g.. ability to include more and / or high powered batteries); and / or (g) faster startup of components (such as a vacuum pump) compared to internal combustion-only vacuum excavators.

[0092] This written description uses examples to disclose the vacuum excavator system described herein, including the best mode and to enable a person of ordinary skill in the relevant art to make and practice the vacuum excavator system described herein, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the vacuum excavator system described herein is defined by the claims. Such other examples are within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. Aspects from the various embodiments described, as well as other known equivalents for each such aspects, may be mixed and matched by one of ordinary skill in the art to construct additional embodiments and techniques in accordance with principles of this application.

Claims

31681-789 (3252WO01)WHAT IS CLAIMED IS:

1. A vacuum excavator system comprising: a vacuum system comprising a vacuum tube and at least one pump, the vacuum system configured to vacuum spoils at an excavation site; a spoils collection tank; a power system comprising at least one power source, the at least one power source configured to provide power to at least the vacuum system; at least one electric motor; and a controller operatively coupled to the power system, the at least one electric motor, and the at least one pump, the controller programmed to provide control signals to control (i) power components of the power system, (ii) the at least one electric motor, and (iii) the at least one pump, wherein the at least one power source is configured to operate in a first mode and a second mode different than the first mode, the at least one electric motor is configured to operate in a first direction in correspondence with the first mode of the at least one power source and in a second direction in correspondence with the second mode of the at least one power source, and the at least one pump (i) pressurizes the vacuum system when the at least one electric motor is operated in the second direction and (ii) creates a vacuum air stream when the at least one electric motor is operated in the first direction.

2. The vacuum excavator system of claim 1, further comprising a plurality of storage tanks, wherein the plurality of storage tanks includes a fluid reservoir tank.

3. The vacuum excavator system of claim 2, wherein the at least one pump includes a vacuum pump, and the vacuum tube is (i) operatively coupled to the vacuum pump, and (ii) configured to vacuum spoils into the spoils collection tank via suction provided at an end of the vacuum tube by the vacuum pump.31681-789 (3252WO01)4. The vacuum excavator system of claim 1, further comprising a turbine operatively coupled to the spoils collection tank near an incoming spoils inlet of the spoils collection tank, wherein the at least one power source includes a battery system, and an incoming flow of spoils via the spoils inlet turns the turbine so that the turbine generates power that is provided to the battery' system for charging one or more batteries of the battery system.

5. The vacuum excavator system of claim 1, further comprising a plurality' of drive components, wherein the plurality of drive components includes a plurality of belt components, and the controller is further programmed to monitor belt slip of the plurality of belt components by calculating an amount of belt slip by comparing a rotational speed of the at least one electric motor and a rotational speed of a drive shaft of the at least one pump.

6. The vacuum excavator system of claim 1, wherein the at least one power source comprises at least one battery configured to power the at least one electric motor, the at least one pump is a vacuum pump, the at least one electric motor is a vacuum pump electric motor for driving the vacuum pump, and the vacuum pump is configured to provide suction when the vacuum pump electric motor is operated in the first direction, the suction occurring at least at an end of the vacuum tube.

7. The vacuum excavator system of claim 1, wherein the at least one power source comprises at least one battery, the at least one electric motor is powered by the at least one battery', and the controller is further programmed (i) with a threshold torque limit to protect the at least one electric motor and components of the vacuum system that are operatively coupled to the at least one electric motor, and (ii) to manage startup torque.

8. The vacuum excavator system of claim 1, further comprising an onboard temperature control system, wherein the at least one power source is a battery system, and the controller is further programmed to control the on-board temperature control system to control cooling and / or heating of the battery system.31681-789 (3252WO01)9. The vacuum excavator system of claim 8, wherein the on-board temperature control system comprises an on-board coolant system.

10. The vacuum excavator system of claim 1, wherein the at least one power source is a hybrid power source comprising an internal combustion engine and an electric power source.

11. The vacuum excavator system of claim 10, wherein the electric power source is an on-board battery system, and the controller is further programmed to control charging of at least one battery of the on-board battery system.

12. The vacuum excavator system of claim 10, wherein the electric power source is an off-board battery system, and the controller is further programmed to control charging of at least one battery of the off-board battery system.

13. The vacuum excavator system of claim 10, wherein the at least one electric motor is operatively coupled to the electric power source, and the internal combustion engine and the at least one electric motor are operated in parallel with one another.

14. The vacuum excavator system of claim 1, wherein the at least one power source is a hybrid power source comprising an internal combustion engine and power from an electric power grid, and the power components condition power from the electric power grid for use in the power system.

15. The vacuum excavator system of claim 1, wherein the at least one power source is a hybrid power source comprising an internal combustion engine and power from an electric generator, and the power components condition power from the electric generator for use in the power system.

16. The vacuum excavator system of claim 1. wherein the at least one power source comprises an electric power source.

17. The vacuum excavator system of claim 16, wherein the electric power source is a batters' system, the at least one electric motor comprises a plurality31681-789 (3252WO01) of electric motors powered by the battery system, and each of the plurality of electric motors is configured to power a different component of the vacuum excavator system.

18. The vacuum excavator system of claim 16, wherein the at least one electric motor comprises a plurality of electric motors, and the controller is further programmed to selectively provide a boost mode in which a maximum allowable cunent draw by any of the plurality of electric motors configured to provide power to the vacuum system is momentarily increased for a prescribed limited time.

19. The vacuum excavator system of claim 16, wherein the electric power source is an on-board battery system, and the controller is further programmed to control charging of at least one battery of the on-board battery system.

20. The vacuum excavator system of claim 16, wherein the electric power source is an off-board battery system, and the controller is further programmed to control charging of at least one battery of the off-board battery system.

21. The vacuum excavator system of claim 16, wherein the electric power source is an electric power grid.

22. The vacuum excavator system of claim 16, wherein the electric power source is an electric generator.

23. The vacuum excavator system of claim 1, further comprising a cutting system comprising a wand and a hose, the wand being configured to cut earthen material at the excavation site when high-pressure fluid from the hose flows through and exits from an end of the wand.

24. The vacuum excavator system of claim 23, wherein the high- pressure fluid is water.

25. The vacuum excavator system of claim 23, wherein the high- pressure fluid is air.

26. The vacuum excavator system of claim 1, wherein the spoils collection tank is configured to be tilted without using a hydraulic-driven actuator.31681-789 (3252WO01)27. The vacuum excavator system of claim 1, wherein the first direction is a forward direction and the second direction is a reverse direction opposite the forward direction.

28. A vacuum excavator system comprising: a vacuum system comprising a vacuum tube and at least one pump, the vacuum system configured to vacuum spoils at an excavation site; a spoils collection tank; a power system comprising at least one power source, the at least one power source configured to provide power to at least the vacuum system; at least one electric motor; a turbine operatively coupled to the spoils collection tank near an incoming spoils inlet of the spoils collection tank, wherein the at least one power source includes a battery system, and an incoming flow of spoils via the spoils inlet turns the turbine so that the turbine generates power that is provided to the battery' system for charging one or more batteries of the battery system; and a controller operatively coupled to the power system, the at least one electric motor, and the at least one pump, the controller programmed to provide control signals to control (i) power components of the power system, (ii) the at least one electric motor, and (iii) the at least one pump.

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