Electric Dump Truck Power Unit Layout for Fast Cooling-Circuit Service
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Solution Overview
Problem
Existing battery electric dump trucks face challenges in efficient power unit installation and maintenance, particularly in large-scale applications, which affect operational efficiency and environmental impact.
Innovation Solution
A battery electric dump truck design featuring a frame with side beams and an upper bridge member, allowing for a power unit to be mounted between these beams, with modular components and a cooling system that can be de-installed with partially filled cooling liquid circuits, and a charging interface unit positioned for easy access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the power unit is designed as a modular one-piece construction, then the ease of installation and maintenance is improved, but the device complexity increases due to integration requirements
Solution Approach 1:
The power unit is segmented into modular components (battery pack, cooling system, control systems) that are pre-assembled as a one-piece construction. This allows the entire power unit to be installed as a single module while maintaining internal modularity for maintenance purposes, resolving the contradiction between ease of installation and device complexity.
Solution Approach 2:
The power unit is designed as a universal module that can be installed in various dump truck configurations. The standardized mounting interfaces and integrated design allow the same modular construction to serve multiple functions and applications, improving ease of installation while managing complexity through standardization.
2Loss of time
If the cooling liquid circuit is designed to remain filled during de-installation, then the loss of time for maintenance is reduced, but the reliability decreases due to potential contamination
Solution Approach 1:
The cooling liquid circuit is extracted as a separate, self-contained system within the modular power unit. This allows the cooling circuit to remain filled during power unit de-installation and re-installation without exposing the cooling liquid to external contamination, reducing maintenance time while maintaining reliability through system isolation.
Solution Approach 2:
The cooling system is designed with sealed connections and contamination prevention features built in before de-installation occurs. This beforehand protection measures ensure that the cooling liquid remains protected from contamination during the maintenance process, allowing quick de-installation without compromising system reliability.
3Ease of operation
If the charging interface unit is positioned for easy access, then the ease of operation is improved, but the device complexity increases due to additional wiring and mounting requirements
Solution Approach 1:
The charging interface unit is positioned as an external or easily accessible component that acts as an intermediary between the power unit and the charging source. This separate positioning provides easy access for charging operations while the standardized wiring harness manages the electrical connections, reducing the complexity impact of the additional wiring requirements.
Data Source
AI summary
The present application relates to a battery electric dump truck, comprising a frame, a dump body pivotably mounted on the frame, a cooling circuit, and a power unit comprising a battery unit and a thermal conditioning unit attached to each other. The power unit provides electrical energy to an electrical propulsion motor of the battery electric dump truck. The thermal conditioning unit comprises at least a first part of the cooling circuit, the cooling circuit comprising valves and connectors for closing off and separating the first part of the cooling circuit of the power unit from a second part of the cooling circuit arranged on the battery electric dump truck, the valves and connectors configured such that the power unit can be de-installed from the battery electric dump truck with the first part and/or the second part of the cooling circuit remaining at least partly filled with cooling liquid.