CN111823885A

CN111823885A - Electric power delivery system and mounting system thereof

Info

Publication number: CN111823885A
Application number: CN202010321381.9A
Authority: CN
Inventors: J.库滕库勒; H.T.杨; A.L.克里沃纳克; M.墨菲; I.齐马舍维奇; N.L.希梅尔赖特; J.J.沃尔夫
Original assignee: GE Global Sourcing LLC
Current assignee: Transportation IP Holdings LLC
Priority date: 2019-04-22
Filing date: 2020-04-22
Publication date: 2020-10-27
Anticipated expiration: 2040-04-22
Also published as: AU2020202350B2; AU2020202350A1; AU2020202350C1; CN111823885B

Abstract

An electrical power delivery system includes a stack of modules, a conductive bus bar, and one or more electrical energy storage devices. The module stack includes a plurality of modules stacked side-by-side, wherein each module has a respective housing and internal electrical components in the housing. The conductive bus bars are oriented parallel to the stacked modules. Bus bars are mounted along the sides of the module stack and are electrically connected to one or more modules. The bus bars are electrically connected to the electrical energy storage device and are disposed between the electrical energy storage device and the stack of modules. The mounting system includes a frame, a guide bar, and a lifting element for mounting the module on the power delivery system. The power delivery system includes a support structure that mechanically supports each of the energy storage devices along at least two support directions that are orthogonal to each other.

Description

Electric power delivery system and mounting system thereof

Technical Field

Embodiments of the inventive subject matter described herein relate to systems for delivering electrical power to various components for performing work.

Background

Some vehicles employ electric wheels for propulsion and dynamic braking. For example, a hybrid vehicle may include an engine coupled with an alternator, rectifier, inverter, etc., which is connected to the wheels of the vehicle by a traction motor. The alternator converts the mechanical energy into electrical energy, which is transmitted to the traction motor, which converts the electrical energy back into mechanical energy to drive the wheels during a propulsion mode of operation.

At least some known power delivery systems, including alternators, rectifiers, inverters, motors, capacitors, resistors, inductors, and the like, arrange these components in a plurality of discrete components that are spaced apart and electrically connected by conductive elements (e.g., cables). For example, an inverter may be positioned proximate to the traction motor, and a rectifier may be spaced apart from the inverter and connected to the inverter by a cable of one or several meters in length. Discrete packaging and spacing between components of a power delivery system may occupy a significant amount of space on a vehicle, which may be in limited supply. Furthermore, long distance transmission of current between various components can result in power losses (e.g., due to electrical resistance along the length of the conductor), which reduces efficiency. Further, the distance between the components may necessitate the use of larger and heavier components (e.g., larger capacitors, etc.) than when the components are more tightly packed, which increases vehicle weight and reduces vehicle fuel efficiency, and further limits the available space on the vehicle. It may be desirable to have systems and methods that differ from those currently available.

Disclosure of Invention

In one or more embodiments, an electrical power delivery system is provided that includes a stack of modules, a conductive bus bar (bus bar), and one or more energy storage devices. The module stack includes a plurality of modules stacked side-by-side along a stack axis. Each module has a respective housing and internal electrical components within the housing. The conductive bus bars are oriented along a plane parallel to the stack axis. Bus bars are mounted along the sides of the stack of modules and are electrically connected to one or more of the modules. The one or more energy storage devices are electrically connected to the bus bar and extend from a side of the bus bar facing away from the module stack such that the bus bar is disposed between the one or more energy storage devices and the module stack.

In one or more embodiments, a mounting system for mounting a module is provided. The mounting system includes a frame, a plurality of guide rods, and a plurality of lifting elements. The frame includes a back wall and a support platform. The guide bar is connected to and extends from the rear wall. The guide rods are suspended above the support platform. A first of the guide bars is spaced a designated height above the support platform such that the first guide bar can be received within the channel of the module when the module is disposed on the support platform. The first guide bar is configured to guide movement of the module relative to the support platform in a loading direction toward the rear wall. The lifting element is arranged at or close to the rear wall. When the module approaches the rear wall, a first lifting element of the lifting elements is configured to: the module is engaged at an angled contact interface between the first lifting element and the module to lift the module off the support platform in response to additional movement of the module in the loading direction. When the module is in a fully loaded position relative to the frame, the module is supported by the back wall, the first lifting element, and/or the first guide bar, and the module is spaced apart from the support platform by a gap.

In one or more embodiments, an electrical power delivery system is provided that includes an electrically conductive bus bar, a plurality of electrical energy storage devices, and a support structure. An electrical energy storage device is mounted and electrically connected to the electrically conductive bus bar. The electrical energy storage devices extend from a common side of the conductive bus bar. The support structure is spaced apart from the conductive bus bar. The support structure engages and at least partially surrounds each of the electrical energy storage devices such that the support structure mechanically supports each of the electrical energy storage devices along at least two support directions that are orthogonal to each other.

Drawings

Referring now briefly to the drawings, in which:

fig. 1 is a schematic circuit diagram of a system according to an embodiment;

FIG. 2 is a perspective view of an electrical power delivery system according to an embodiment;

fig. 3 is a first front perspective view of a module of the electrical power delivery system according to an embodiment;

FIG. 4 is a second front perspective view of the module shown in FIG. 3;

FIG. 5 is a rear perspective view of the module shown in FIGS. 3 and 4;

fig. 6 is a front perspective view of the module shown in fig. 3-5 in a first partially assembled state, according to an embodiment;

fig. 7 is a front perspective view of the module of fig. 3-6 in a second partially assembled state, according to an embodiment;

fig. 8 is a diagram illustrating stacking of components within a housing of the module shown in fig. 3-7, according to an embodiment;

fig. 9 is a first front perspective view of a module of the electrical power delivery system according to an embodiment;

FIG. 10 is a front perspective view of the electrical power delivery system of FIG. 2, showing a connector side of the module stack according to an embodiment;

FIG. 11 is a front perspective view of an electrical power delivery system according to an embodiment;

FIG. 12 is a front perspective view of the electrical power delivery system of FIG. 11 with the module stack omitted, in accordance with embodiments;

fig. 13 is a perspective view of a mounting system for mounting modules in a stack of modules according to an embodiment;

fig. 14 is a side cross-sectional view of a mounting system showing a first module of the stack of modules ready for installation, according to an embodiment;

fig. 15 is a side cross-sectional view of a mounting system showing a first module in a first intermediate load position relative to a rack, under an embodiment;

FIG. 16 is an enlarged cross-sectional view of a portion of the mounting system shown in FIG. 15;

FIG. 17 is an enlarged cross-sectional view of a portion of the mounting system shown in FIGS. 15 and 16, showing the module during a second loading stage, in which the module is moved laterally and vertically relative to the rack;

fig. 18 is a cross-sectional view of the mounting system of fig. 15-17 showing a module in a fully loaded position relative to a rack, under an embodiment;

FIG. 19 is a side cross-sectional view of a mounting system showing a first module in a fully loaded position and a second module ready for installation, according to an embodiment;

fig. 20 is a cross-sectional view of a mounting system showing both a first module and a second module in a fully loaded position relative to a rack, according to an embodiment;

fig. 21 is a side view of a mounting system showing four modules mounted to a rack in a stack of modules, according to an embodiment;

FIG. 22 is a cross-sectional view of the mounting system showing a first intermediate loading stage of the first module in accordance with the first alternative embodiment;

FIG. 23 is a cross-sectional view of the mounting system of FIG. 22 showing a second intermediate loading stage of the first module in accordance with the alternative embodiment;

FIG. 24 is a cross-sectional view of the mounting system according to the alternative embodiment shown in FIGS. 22 and 23, showing the first module in a fully loaded position;

FIG. 25 is a cross-sectional view of the mounting system showing an intermediate loading stage of the first module in accordance with the second alternative embodiment;

FIG. 26 is a cross-sectional view of the mounting system of FIG. 25 showing the first module in a fully loaded position, according to an alternative embodiment;

FIG. 27 is a perspective view of a portion of the electrical power delivery system of FIG. 2;

FIG. 28 is a side view of the electrical power delivery system showing two support structures according to the embodiment shown in FIG. 27;

figure 29 is a perspective view of a portion of the first housing member of one of the support structures shown in figures 27 and 28, according to an embodiment;

FIG. 30 is a perspective view of a portion of the second housing member of the support structure;

figure 31 illustrates a portion of one of the support structures illustrated in figures 27-30 in a partially assembled state, in accordance with an embodiment;

FIG. 32 illustrates a portion of the support structure of FIG. 31 in a fully assembled state, in accordance with an embodiment;

FIG. 33 illustrates a support structure for mechanically supporting a plurality of electrical energy storage devices of an electrical power delivery system, in accordance with a first alternative embodiment;

FIG. 34 illustrates a support structure for mechanically supporting a plurality of electrical energy storage devices of an electrical power delivery system, in accordance with a second alternative embodiment; and

FIG. 35 illustrates a support structure for mechanically supporting a plurality of electrical energy storage devices of an electrical power delivery system, according to a third alternative embodiment.

Detailed Description

Embodiments of the inventive subject matter described herein relate to systems for delivering electrical power to various components for performing work. Certain embodiments relate to a system for delivering electrical power to a motor on a vehicle. In one embodiment, an electrical power delivery system is provided. The system may include a stack of modules, a conductive bus bar, and one or more energy storage devices. The module stack may include a plurality of modules stacked side-by-side along a stack axis. Each module may have a respective housing and internal electrical components within the housing. The conductive bus bars can be oriented along a plane parallel to the stack axis, mounted along the sides of the stack of modules, and electrically connected to one or more of the modules. The energy storage device may be electrically connected to the bus bar and extend from a side of the bus bar facing away from the module stack such that the bus bar is disposed between the energy storage device and the module stack.

In one or more embodiments, a mounting system for mounting one or more modules on an electrical power delivery system is provided. The system may include a frame, a guide bar, and a lifting element. The guide bar may extend from a rear wall of the frame and may be suspended above a support platform of the frame. A first of the guide bars may be spaced a designated height above the support platform to be received within the channel of the module when the module is disposed on the support platform. The first guide bar may guide movement of the module toward the rear wall. As the module approaches the back wall, a first lifting element of the lifting elements may engage the module at an angled contact interface to lift the module off of the support platform in response to additional movement of the module toward the back wall. When the module is fully loaded, the module may be supported by the rear wall, the first lifting element and/or the first guide bar. The module may be spaced apart from the support platform by a gap.

In one or more embodiments, an electrical power delivery system includes an electrically conductive bus bar, at least one energy storage device, and a support structure. A plurality of electrical energy storage devices are mounted on and electrically connected to the electrically conductive bus bars. The electrical energy storage devices extend from a common side of the conductive bus bar. The support structure is spaced apart from the electrically conductive bus bar and engages and at least partially surrounds at least one of the electrical energy storage devices such that the support structure mechanically supports the corresponding device along at least two support directions that are substantially orthogonal to each other.

A schematic circuit diagram of a system 100 according to an embodiment is shown in fig. 1. The system may be a power delivery system that may be used for propulsion. The system may be onboard. The system may include a bus bar 102. The bus may have a positive rail 104 and a negative rail 106. The system may include an engine 108 and an alternator 110. The alternator may be mechanically coupled to the engine via a mechanical linkage 112. The mechanical linkage may be a shaft.

Suitable engines may be diesel engines, gasoline engines, multi-fuel engines, and the like. The engine drives the alternator via a mechanical linkage, for example, by rotating a rotor of the alternator via a rotating shaft. The alternator and engine may be selected with reference to their performance characteristics relative to each other (e.g., torque output of the engine versus torque acceptance level of the alternator, engine speed versus alternator speed, etc.) and further with reference to the intended end-use application. Various components and materials may be selected depending on the voltage, current requirements of the application. In addition, the spacing and air gap may determine the spacing and insulation values of some components. Finally, thermal considerations may be used to select the appropriate components for such end use applications.

With respect to the alternator 110, the alternator receives mechanical torque and generates electrical energy (e.g., electrical current) from the mechanical torque, which is transmitted along the bus 102 to various components to power various loads. The alternator is electrically connected to the rectifier 114. The alternator converts mechanical energy from the engine into electrical current in the form of Alternating Current (AC) (referred to herein as AC current). The rectifier receives AC current from the alternator and converts the AC current into a current in the form of Direct Current (DC) (referred to herein as DC current). The DC current output from the rectifier is supplied to the positive rail of the bus. The bus including the positive and negative rails may be referred to as a DC link, which provides DC current to various components of the system.

The system may include two motor subassemblies 116 connected between the positive and negative rails of the bus bar. Each motor subassembly may include a respective inverter 118 and traction motor 120. The inverters are labeled INV1 and INV2 in fig. 1, and the traction motors are labeled TM1 and TM 2. The two motor subassemblies may be coupled to wheels on the same axle or different axles of the vehicle. The traction motor may be an AC motor. The inverter may convert the DC current from the rectifier to three-phase AC current for the respective traction motor. The system optionally may have more or less than two motor subassemblies. In another embodiment, the motor may be a DC motor, wherein the inverter is configured to convert DC from the DC link into a DC power waveform suitable for powering the DC motor.

The system may also include at least one chopper circuit 126 (referred to herein as a chopper) electrically connected to the resistive grid 122. The resistive grid may include resistive elements 128 configured to dissipate current as heat. The chopper controls the flow of current to the resistive grid. In the illustrated embodiment, the chopper is connected in series with one or more of the resistive elements to define a resistor branch 124 connected between the positive and negative rails. Only one chopper and only one resistor branch are shown in fig. 1, but in another embodiment the system may have multiple choppers and/or multiple resistor branches arranged in a parallel orientation. The resistive grid optionally may include a physical housing structure. The resistive grid is configured to dissipate thermal energy (e.g., heat) generated during dynamic braking. Optionally, the resistive grid may also include one or more blowers for enhancing the dissipation of heat from the grid box to the external environment. The chopper can be used to adjust a desired voltage on a bus (e.g., a DC link) by modulating the effective resistance along the resistor branch between the positive and negative rails. The chopper can regulate the current along the bus and prevent high power demands on the engine during transitions between propulsion and dynamic braking modes of operation. Although the chopper is shown in fig. 1 as being separate from the resistive grid, the chopper may optionally be incorporated into the resistive grid.

A chopper is an electronic switching device that is controlled to switch between an open state and a closed state. In the open state, the chopper does not conduct current from the positive rail through the respective resistor branch. In the closed state, the chopper conducts current through the resistor branch. When the chopper is in the closed state, at least some of the current conducted along the resistor branch is converted into heat, which is dissipated from the grid box. The chopper may include internal electrical components such as one or more transistors, diodes, inductors, and the like. The transistors may comprise or represent insulated gate bipolar junction transistors (IGBTs) or other types of transistors. The resistive element may be a resistor that converts electrical energy into thermal energy. Although shown in FIG. 1 as being separate from the chopper, in some embodiments the resistive element may be an integral component of the chopper. The operation of the chopper can be controlled by received signals generated by one or more processors.

The system is capable of selectively switching to different modes of operation. These operating modes may include a propulsion mode and a dynamic braking mode. In the propulsion mode, electrical energy may be generated by an alternator (which is powered by the engine) and transmitted along a bus to the traction motors for powering propulsion. Propelling may include propelling a vehicle on which the system is integrated. For example, the traction motor may be mechanically coupled to a wheel of the vehicle and may rotate the wheel based on the received electrical energy. In the dynamic braking mode, the alternator is not available to propel the vehicle. Instead, the vehicle operates in a dynamic braking mode, decelerating the vehicle by using the vehicle momentum and the existing rotational torque of the wheels to generate electrical energy via the traction motor (rather than the alternator). The current generated by the traction motor may be supplied to the bus. Dynamic braking may be used alone or in combination with friction-based brakes to slow a vehicle. In one embodiment, at least some of the electrical energy generated by the traction motor may be transferred to a resistive grid to dissipate the energy as heat. Alternatively, if an electrical energy storage system is present, at least some of the electrical energy may be directed to a battery or another electrical storage device for storage and future use of the electrical energy. Alternatively, some electrical energy may be used in real time to power various electronic devices (e.g., compressors, lights, pumps) that consume electrical power.

Fig. 2 is a perspective view of an electrical power delivery system 200 according to an embodiment. The electrical power delivery system has an integrated modular design and may represent a portion of the system shown in fig. 1. For example, the electric power delivery system may represent several components and/or circuits of a system disposed between alternator 110 and traction motor 120, such as rectifier 114, bus 102 (e.g., a DC link), chopper 126, and inverter 118. The electrical power delivery system may include alternative or additional components (of similar or dissimilar type or configuration) than those in the system of fig. 1, and/or may lack one or more of the components included in the system.

An electrical power delivery system supplies electrical current to power one or more loads. The electrical power delivery system may be incorporated into a vehicle, such as an OHV, rail vehicle (e.g., locomotive), marine vessel, automobile, etc., for the purpose of delivering electrical current having specified properties to a motor for propelling the vehicle. The specified property may include the form (i.e., electrical waveform) of the current (e.g., DC or AC), the phase of the current, the voltage of the current, the flow of the current, and so forth. The electrical power delivery system may be configured to convert, modify, and/or transform the received electrical current to supply the electrical current having specified properties to the load. In one or more embodiments, the electrical power delivery system receives electrical current from an alternator on the vehicle and supplies electrical current to one or more traction motors used to rotate wheels or propellers of the vehicle.

In one embodiment, the electrical power delivery system may be relatively compact. Compact packaging is a technical effect because it can reduce the footprint, thereby taking up less space. Furthermore, the electrical power delivery system presented herein may be modular. The modularity may enable quick and efficient repair and replacement of components. Due to modularity and compactness, close proximity of the components may reduce drag-based energy losses, and a reduction in size and/or weight of at least some of the components may be achieved.

The electrical power delivery system 200 may include various components coupled together in discrete packages. These components include a module stack 202 of a plurality of modules 204, a conductive plane (meaning a planar body made of metal or otherwise capable of conducting electricity, such as a bus bar) 206, and one or more electrical energy storage devices 208. The modules in a stack of modules (also referred to herein as a stack) are arranged side-by-side along a stack axis 210. Each module may include a housing 212 and internal electrical components (shown in fig. 6-9) held by and/or within the housing. The stack may be arranged such that the stack axis is vertically oriented. For example, the stack axis can be parallel to the direction of gravity (gravitational force) or substantially parallel to the direction of gravity (e.g., within a specified margin of +/-1%, 2%, 5%, 1 °, 2 °, 5 °, etc. from the direction of gravity). For example, the first module 204A is the lowermost module in the stack, the second module 204B is immediately above the first module 204A, the third module 204C is immediately above the second module 204B, and the fourth module 204D is the uppermost module in the stack. The second and

third modules

204B, 204C are internal modules in the stack because these modules are bounded by the first and

fourth modules

204A, 204D, which represent external modules at corresponding ends of the stack. In alternative embodiments, the modules may be stacked in different arrangements, such as on a stack axis orthogonal to the vertical (or height) axis. The stack optionally can include more or less than four modules to meet application specific parameters.

The modules have functions related to current modification, transmission, distribution, dissipation, etc. For example, the internal electrical components of the module may include transistors, diodes, inductors, conductors, switches, control circuit boards, connectors, and the like, as described in more detail herein. In an embodiment, at least two of the modules in the stack have different functions from each other. For example, one of the modules may be used to dissipate current and another of the modules may be used to distribute and/or modify current. Optionally, at least two of the modules in the stack can be used to provide the same function as each other.

The housings of the modules may have the same form factor as one another. The form factor refers to the overall size and shape of the housing, e.g., the overall dimensions along three mutually perpendicular axes. Two housings having the same form factor may not be identical to each other due to differences in materials, number, location, size, and/or shape of openings through the walls of the housings, number, location, size, and/or shape of features on the walls of the housings, and the like. In fig. 2, all four modules in the stack have the same form factor. For example, the housing has a rectangular prismatic shape (e.g., parallelepiped) with a lateral width and a longitudinal depth greater than a vertical height (along the stacking axis).

In an embodiment, at least two of the modules have different internal electrical components from each other. For example, the internal electrical components of the fourth module 204D may have a different configuration than the internal electrical components of the third module 204C. The configuration of the internal electrical components may refer to the type of electrical components and the arrangement of the components in the assembly within the respective module. The respective configuration of the internal electrical components influences the function of the module. In an embodiment, the internal electrical components of at least two of the modules in the stack have the same configuration as each other, such that the at least two modules have the same type and arrangement of electrical components. For example, the internal electrical components of the fourth module 204D may be of the same configuration as the internal electrical components of the second module 204B. Modules having the same internal component configuration may be duplicates (or copies) of each other such that they are made of the same type of components and produced using the same manufacturing and assembly steps.

In an embodiment, at least one of the modules is an inverter module having functionality similar to each of the inverters 118 of the system 100 shown in fig. 1. The inverter module may receive the current and modify the current to have specified electrical characteristics or properties for use by a particular load, such as a traction motor. For example, the inverter module may convert DC current to AC current for use by a particular load.

In an embodiment, at least one of the modules in the stack is a rectifier module having a function similar to the rectifier 114 shown in fig. 1. The rectifier module may receive AC current from a power source (e.g., an alternator) and may convert the AC current to DC current. The rectifier module may also distribute the DC current to various other modules in the stack, such as to one or more inverter modules.

The modules in the stack may also include at least one chopper module, which functions similarly to the chopper 126 shown in FIG. 1. The chopper module may be configured to dissipate the current as heat by transferring the received current to a resistive grid, which may include one or more resistive elements, among other functions. The chopper module may receive current from the rectifier module.

In a non-limiting exemplary embodiment, the stack can include two inverter modules, one rectifier module, and one chopper module. The rectifier module is configured to distribute current received from the power source to the two inverter modules. Positioning the rectifier modules between the inverter modules allows for similar current path distances from the rectifier modules to each of the inverter modules, which may achieve a more uniform current distribution than when the rectifier modules are disposed at the ends of the stack. The two inverter modules may supply the current received from the rectifier modules to corresponding loads, for example to two different traction motors. The chopper module can be disposed at an end of the stack. The chopper can generate and emit waveform pulses out of and/or toward the resistive grid along a current loop. Because of the greater separation distance from the chopper to at least some of the other modules, positioning the chopper module at the end of the stack can reduce the effect of electromagnetic interference (EMI) on the modules in the stack due to the waveform pulses compared to when the chopper module is more centrally positioned.

In a particular arrangement of the above non-limiting exemplary embodiment, the first module 204A is a chopper module, the second module 204B is a first inverter module, the third module 204C is a rectifier module, and the fourth module 204D is a second inverter module. Thus, the first inverter module 204B is disposed between the rectifier module and the chopper module. Optionally, a second inverter module may be placed at the top end of the stack for thermal damage suppression and/or mitigation purposes. For example, because the generated heat and fire travel vertically upward, if a second inverter module at the top of the stack ignites or experiences thermal runaway, the likelihood of thermal damage spreading downward to other modules in the stack is reduced as compared to when the same inverter module is located below the other modules in the stack. Furthermore, the uppermost module may be the most exposed module in the stack, providing the greatest access for active cooling and fire suppression techniques such as pouring a fire retardant over the module. For this reason, the stack may be arranged such that the inverter module with the greatest potential for fire and/or thermal runaway is placed at the top of the stack and another inverter module is placed below, between the rectifier module and the chopper module. In an alternative embodiment, the chopper module may be located at the top of the stack and the rectifier module may be the second module 204B between the two inverter modules. The arrangement of the modules may be based on the orientation and/or location of an electrical power delivery system on board the vehicle, such as relative to a cooling fluid, relative to a traction motor, relative to an electrical energy power source (e.g., an alternator), and so forth.

The conductive plane (plane)206 of the electrical power delivery system 200 is referred to herein as a bus bar. The bus bars are electrically connected to one or more modules in the stack. For example, the bus bars may be electrically connected between the rectifier module and the inverter module to transfer current from the rectifier module to the inverter module. The bus bar may operate as a DC link, similar to the bus 102 shown in FIG. 1. The bus bar may include a plurality of conductive layers laminated together. The conductive layer may be a metal sheet. The bus bars may be planar and oriented along a plane 214. In the illustrated embodiment, the plane of the bus bar is parallel to the stack axis 210 of the module stack. The bus bars are mounted along the side 216 of the module stack and extend across a plurality of modules. The sides 216 of the stack are referred to herein as the bus bar sides. The bus bar has a first side 218 and a second side 220 opposite the first side 218. The first side 218 faces the module stack. Second side 220 faces away from the stack of modules. The bus bars can be mounted to the module stack via one or more fasteners, such as bolts, screws, nuts, clamps, clips, and the like. The bus bars may be individually electrically connected to the modules via one or more conductors extending between the first side of the bus bar and the bus bar side of the module stack. The conductors may include rigid metal contacts, flexible cables, and the like.

The rectifier module may be centrally positioned within the stack as one of the internal modules to achieve a uniform and even current distribution (relative to positioning the rectifier module at the end of the stack) from the rectifier module row to the inverter module along the bus bars. For example, the rectifier modules may supply DC current to the bus bar along a central region of the bus bar, and the bus bar spreads or distributes the current in opposite directions (up and down) to different inverter modules. Arranging the components such that the current spreads in opposite directions along the bus bar may reduce localized heat loads on the bus bar and/or the modules. Reducing the local thermal load may reduce the risk of heat related damage due to fire, thermal runaway, etc., and may extend the operational life and/or improve the performance capabilities of the electrical power delivery system 200.

In the illustrated embodiment, the electrical power delivery system may include a plurality of electrical energy storage devices 208 mounted to and electrically connected to the bus bars. The electrical energy storage devices collectively extend from the second side 220 of the bus bar (e.g., in a direction away from the stack of modules). Thus, the bus bars are disposed between the energy storage device and the module stack. In an embodiment, the energy storage device is a capacitor, e.g. a DC-link filter capacitor. The electrical energy storage device is referred to herein as a capacitor, however, another type of electrical energy storage device, such as a battery or fuel cell, may be used in addition to or in place of the capacitor, depending on the application specific requirements.

The capacitors are cylindrical and extend from the bus bars along respective central axes 222. In the illustrated embodiment, the capacitors extend from the bus bars such that the central axes 222 are parallel to each other and perpendicular to the stack axis 210. The central axis 222 may be perpendicular to the plane 214 of the bus bar. In the illustrated embodiment, the electrical power delivery system may include an array of eight capacitors, but may have more or fewer capacitors in other embodiments. The capacitors may have the same construction, or at least some of the capacitors may have different constructions (e.g., different sizes, solid-to-solid (vs.) electrolytes, polymer-to-ceramic, etc.). In the illustrated embodiment, the capacitors are disposed proximate the module stack such that only the thickness of the bus bar between the first side 218 and the second side 220 can separate the capacitors from the module stack. The close proximity of the capacitors to the module stack may allow for a reduction in the number of capacitors and/or the size of the capacitors relative to the number and/or size of capacitors needed to provide a similar degree of performance when the capacitors are spaced further from the module stack.

The electrical power delivery system 200 shown in fig. 2 has a relatively compact modular shape that may be used in a variety of applications, including vehicle applications. For example, the rectifier module may be electrically connected to a power source on the vehicle, such as an alternator powered by the engine. Optionally, the side 224 of the module stack opposite the bus bar side 216 may have electrical connectors for electrically connecting the modules to conductors, such as cables and wires, that carry current to and from devices remote from the electrical power delivery system. Side 224 is referred to herein as connector side 224. In an embodiment, the rectifier modules are electrically connected to one or more cables or other conductors extending from the connector side 224 of the module stack to the alternator (or other power source) for delivering current to the rectifier modules. The rectifier module may receive AC current from the alternator and convert the AC current to DC current. The rectifier module supplies DC current to the bus bar, which distributes the DC current to the two inverter modules. The inverter module may convert the received DC current to AC current and transmit the AC current to a remote location. For example, each of the inverter modules may be electrically connected to a different corresponding traction motor for rotating one or more wheels and/or one or more propellers of the vehicle via one or more cables or other conductors. The cables may extend from the inverter modules along the connector side 224 of the module stack.

In a non-limiting example, the electric power delivery system may be implemented on an OHV, such as a large mining truck. The rated payload of the OHV may weigh up to or in excess of 100 tons. The electric power delivery system is configured to provide electric current to the traction motor for rotating the large wheels of the OHV. For example, an OHV may have a nominal system power of 1200 horsepower. System power may be delivered to the traction motors by an electric power delivery system.

Fig. 3 is a first front perspective view of a module 300 of an electrical power delivery system according to an embodiment. Fig. 4 is a second front perspective view of the module 300 shown in fig. 3. Fig. 5 is a rear perspective view of the module 300 shown in fig. 3 and 4. The module 300 may be one of the modules 204 of the electrical power delivery system 200 shown in fig. 2. The module 300 may include a housing 302 and internal electrical components 304 held by the housing 302.

The housing of the module extends from a front end 306 to a rear end 308 opposite the front end 306. The front end is visible in fig. 3 and 4. The rear end is visible in fig. 5. The housing may include a front side 310 at a front end and a rear side 312 at a rear end. The housing also has several walls extending from the front side 310 to the back side 312, including a top side 314, a bottom side 316, a bus bar side 318, and a connector side 320. The bottom side is opposite the top side. The bus bar side is opposite the connector side. When assembled in a module stack, the bus bar side of the module can define a portion of the bus bar side 216 (shown in fig. 2) of the module stack, and the connector side of the module can define a portion of the connector side 224 (fig. 2) of the module stack. The view in fig. 3 shows the front side, the top side and the connector side of the housing. The view in fig. 4 shows the front side, the bottom side and the busbar side. The view in fig. 5 shows the back side, the top side and the busbar side. In a non-limiting example, the height of the housing between the top side and the bottom side can be between 4 and 10 inches, such as about 6 inches (e.g., within 0.5 inches thereof); the lateral width of the housing between the bus bar side and the connector side can be between 18 and 24 inches, for example about 21 inches; and the longitudinal depth of the housing between the front and rear sides (excluding the shelves) may be between 16 and 21 inches, for example about 18 inches.

In an embodiment, the enclosure may include a frame 322, an upper panel 324, and a lower panel 326. The frame may be a seamless unitary, one-piece (e.g., one-piece) body. Optionally, the frame may be a unitary body constructed of a composite material such as glass-filled polyester. The top panel is mounted to the frame 322 to define at least a portion of the top side of the housing. The lower panel is mounted to the frame 322 to define at least a portion of the bottom side of the housing. The upper and lower panels may be generally planar except optionally along edges thereof for coupling to the frame. The housing may include a shelf 328 that projects forwardly beyond the front side such that a distal end of the shelf defines the front end of the housing. The shelf may be coplanar with the top panel. For example, the top of the shelf may define a portion of the top side of the housing. In the illustrated embodiment, the rack may include one or more handles 330 for manually moving (e.g., sliding) the modules relative to the stack of modules, such as for loading or removing modules from the stack. In alternative embodiments, the frame may be an assembly of a plurality of discrete frame components coupled together at joints via fasteners, adhesives, or the like.

The housing defines a front plenum (plenum) opening 332 through the front side 310 and a rear plenum opening 334 through the rear side 312. The front and rear plenum openings are fluidly connected to an interior cavity 336 (shown in fig. 6) of the housing to provide a passage for a cooling fluid (e.g., air) through the housing to absorb and dissipate heat from the module. In the illustrated embodiment, the module may include a plenum cushion 338 mounted to the rear side and surrounding the rear plenum opening. The plenum cushion can be at least partially embedded in the rear side, such as within a groove along the rear side. The plenum gasket is at least partially compressible to provide a seal between the housing and the rear wall of the chassis when the module is loaded into the stack. The housing may also include a channel 340 extending longitudinally through the housing from the front end to the rear end. The channel is open along the front and rear sides. The channels are configured to receive guide rods therein for aligning and guiding movement of the modules relative to the module stack as the modules are loaded and unloaded.

In an embodiment, one or more of the internal electrical components 304 of the module may protrude out of the housing to be exposed along the exterior of the housing. For example, a number of conductive power tabs (tab)342 are exposed along the connector side of the housing. The power tabs 342 are configured to electrically connect to one or more electrical connectors for transmitting electrical current to and/or from the module stack to a remote device, such as a power source or load. The module may also include a number of connectors 344 mounted to the housing along the side of the connector near the front side. Connector 344 may be used, for example, to connect wires for transmitting control signals and/or data signals to control components within the module to control the operation of the module.

Fig. 6 is a front perspective view of the module 300 shown in fig. 3-5 in a first partially assembled state, according to an embodiment. Fig. 7 is a front perspective view of the module 300 of fig. 3-6 in a second partially assembled state, according to an embodiment. The top panel is remote from the frame 322 of the housing 302 to show the internal electrical components 304 within the internal cavity 336 of the housing. In fig. 6, the module may include a heat sink 346 and internal electrical components mounted on the heat sink. The internal electrical components may include transistors 348, such as insulated gate bipolar junction transistors (IGBTs) and the like. The internal electrical components may also include a gate driver 350 electrically connected between the transistors and a ribbon cable 352. The internal electrical components disposed above the heat sink 346, including transistors and gate drivers, may represent power electronics 354 for processing (e.g., receiving and supplying) and/or modifying (e.g., converting and transforming) the current used to power the load.

In fig. 7, the internal electrical components also include a conductive bus bar 356 mounted on the power electronics 354 shown in fig. 6. The conductive bus bar is electrically connected to the transistors. Each of the conductive bus bar rows may include one or more conductive layers laminated. The bus bars electrically connect the power electronics within the enclosure to conductive power tabs 342 along the exterior of the enclosure.

In a non-limiting example, module 300 may represent one of an inverter module in a module stack and/or a chopper module in a module stack. For example, the inverter module and the chopper module may have internal electrical components (e.g., components of the same type and arrangement) with the same configuration, however the inverter module is used to perform a different function than the chopper module. Thus, the illustrated module can optionally be used as either an inverter module or a chopper module.

Fig. 8 is a diagram illustrating stacking of components within a housing of the module 300 shown in fig. 3-7, according to an embodiment. A conductive bus bar 356 (shown in fig. 7) is disposed at the top of the stack immediately above the power electronics 354 (fig. 6). The electrical power electronics are disposed immediately above a heat sink 346 (fig. 6), the heat sink 346 being referred to as a first heat sink. The first heat sink is disposed immediately above the second heat sink 360, and the second heat sink 360 is immediately above the control electronics 362. The control electronics may include one or more circuit boards, integrated circuits, etc., that include one or more processing devices for controlling the operation of the module. The control electronics may be mounted directly on the second heat sink. One or both of the heat sinks may include fins for dissipating heat into the cooling air flowing through the internal cavity of the housing between

plenum openings

332 and 334 shown in fig. 3-5. The electrical power electronics and control electronics are spaced along opposite sides of the heat sink (and cooling air flows through the heat sink). In alternative embodiments, the module may have a single heat sink or at least three heat sinks, depending on the amount of heat dissipation required for a particular application.

Fig. 9 is a first front perspective view of a module 400 of an electrical power delivery system according to an embodiment. The module may be one of the modules 204 of the electrical power delivery system 200 shown in fig. 2. The module 400 may include a housing 402 and internal electrical components 404 held by the housing 402. The top panel of the housing is omitted in fig. 9 to show some of the internal electrical components 404 within the housing 402 that would otherwise be masked by the top panel. The housing 402 may be a duplicate of, or at least similar to, the housing 302 of the module 300 shown in fig. 3-7. For example, the housing 402 may have the same form factor as the housing 302. As described above, all modules in a stack of modules can have the same form factor, such as the same size (e.g., dimension) and shape.

In a non-limiting example, the module 400 in fig. 9 may represent a rectifier module (e.g., 204C) of the module stack 202 in fig. 2. At least some of the internal electrical components 404 of the rectifier module 400 are different from the internal electrical components 304 of the inverter and/or chopper module 300. For example, the module 400 has a single conductive bus bar 406 rather than a plurality of discrete bus bars. The bus bars are mechanically and electrically connected to three power tabs 342 extending along the exterior of the housing 402 for connection to cables. Cables may connect the rectifier module 400 to an alternator or other power source. In addition to the differences in the bus bars, the internal electrical components 404 of the rectifier module 400 may have other differences relative to the internal electrical components 304 of the inverter and/or chopper module 300. For example, the rectifier module 400 may have a snubber circuit (snubber) board in place of the second heat sink 360 (shown in fig. 8) and a snubber circuit card in place of the control circuit board or integrated circuit. The rectifier module 400 may also have different diodes and/or other components than the module 300. Optionally, the rectifier module 400 may include a heat sink that is a replica of, or at least similar to, the heat sink 346 of the module 300 shown in fig. 6 and 8.

Fig. 10 is a front perspective view of the electrical power delivery system 200, showing the connector side 224 of the module stack 202 according to an embodiment. The conductive power tabs 342 of the modules 204 are connected to corresponding cables 502 that extend away from the module stack. For example, cables connected to the power tabs of the

inverter modules

204B, 204D may extend to different corresponding traction motors or other loads. The cables connected to the rectifier module 204C may extend to an alternator or another power source. The cables connected to chopper module 204A may extend to the resistive grid for dissipating the electrical energy as heat.

The electrical power delivery system may include a frame 504 with the modules mounted on the frame 504. The frame structurally supports the modules. The rack may include a rear wall 506 and one or more support platforms 508. In the illustrated embodiment, the frame has two support platforms. The support platform is disposed below the stack of modules. The rear wall may be a partition separating and separating the two spaces. When a module is loaded into the module stack, the rear side of the module, or at least the plenum cushion 338 thereon (shown in fig. 5), may engage and abut against the rear wall. Optionally, bus bars 206 mounted along the module stack may be independently mounted to the rack.

As described in more detail herein, the chassis supports the modules such that the modules in the stack of modules are not directly engaged with each other. For example, the modules are spaced apart from one another by a spacing gap 510 defined between adjacent modules in the stack. For example, a given spacing gap is defined between the bottom side of an upper module in an adjacent pair of modules and the top side of a lower module in the adjacent pair of modules. The spacing gap enables air to flow between the modules for dissipating heat and limiting and/or inhibiting the spread of fire and/or thermal runaway between the modules. The spacing gap also enables the modules to be removed independently one at a time in any order, as the lower modules in the stack do not support the weight of the upper modules in the stack. Although not clearly shown in fig. 10, even the lowermost first module 204A may be spaced from the support platform by a spacing gap when the first module is fully loaded in the module stack. The first module may temporarily engage and slide along the support member when loading and unloading the first module, but is configured to disengage from the support member before reaching the fully loaded position, as described in more detail herein.

In an embodiment, the electrical power delivery system 200 may also include a support member 512 spaced apart from the rear wall 506. The support member is mechanically coupled to a plurality of modules in the stack and is configured to provide reinforcing support for the modules. In the illustrated embodiment, the support member is coupled to the module at its front side 310, for example via bolts and nuts or other fasteners. The support member may be or include a metal angle extending along two orthogonal planes and coupled to each module at a corner between the front side of the module and the connector side 320 of the module. The support members may bind the modules together to reduce movement of the modules relative to each other. For example, during movement of a vehicle on which the electrical power delivery system is disposed, the support members may reinforce the module stack to maintain the size of the spacing gap when exposed to applied forces such as vibration, acceleration, and impact forces. Further, the support member may be electrically conductive and may be used to provide an electrical ground path. For example, the support members may connect the ground elements of each module to the chassis to electrically share and ground the ground elements.

Fig. 11 is a front perspective view of an electrical power delivery system 200 according to an embodiment. In the illustrated embodiment, the electrical power delivery system 200 may include a housing 600. The module stack 202, bus bar 206, and energy storage device 208 are collectively housed within the housing. A housing 504 (shown in fig. 10) may also be housed within the housing. The housing has a box shape with a number of walls including a front wall 602, two opposing side walls 604, a bottom wall 606 below the support platform 508, a top wall (not visible in fig. 11) and a rear wall 608 opposite the front wall. Several walls, including a front wall and two side walls, define a window 610 therethrough for accessing components within the housing and/or allowing air to flow through the housing. The housing optionally may have additional windows and/or other types of openings to ensure air flow through the housing and reduce weight. The housing may enable the electric power delivery system to move as a single modular unit. The housing may also protect the components of the system from external impacts and damage from debris and contaminants. Alternatively, the housing may be integrated into the housing as an integral part of the housing, rather than being contained within the housing.

Fig. 12 is a front perspective view of the electrical power delivery system 200 shown in fig. 11 with the module stack omitted, according to an embodiment. The bus bar 206 may be mounted to the enclosure 600 and/or the rack 504 via one or more mounting brackets 612. In the illustrated embodiment, the vertically oriented bus bar is coupled to the mounting bracket at both the top and bottom ends of the bus bar. In an embodiment, the rear wall 506 of the chassis defines a slot 614 therethrough. The slots are configured to align with rear plenum openings 334 of modules 204 (shown in fig. 5) when the modules are mounted to the rack to allow air to flow into the modules through the rear wall for cooling the internal electrical components in the modules.

Fig. 13 is a perspective view of a mounting system 700 for mounting a module in a stack of modules, according to an embodiment. As shown in fig. 2 and 10, the mounting system 700 may be used to mount the modules 204 of the electrical power delivery system 200 in the module stack 202. However, the mounting system is not limited to use with the modules 204 of the electrical power delivery system 200, as the mounting system may be used to mount other types of modules, such as server modules in a server rack, drawers in a cabinet or furniture, and the like.

The mounting system may include a frame 702, a plurality of guide rods 704, and a plurality of lifting elements 706. The installed modules may also represent components of the installation system. The modules are not shown in fig. 13. The rack may include a back wall 708 and at least one support platform 710. In the illustrated embodiment, the gantry has two support platforms 710. The rack may be the same as or similar to the rack 504 shown in fig. 10, such that the back wall 708 represents the back wall 506 and the two support platforms 710 represent the support platforms 508.

The guide rods 704 may mechanically align and guide the mounting of the modules to the rack. For example, the guide rods may engage the modules to ensure that the modules are properly aligned with the rack when the modules are loaded onto the rack. The guide rods are mechanically coupled to the rear wall 708. The guide rods extend from the front side 712 of the rear wall. The front side faces the modules in the stack (when the modules are mounted). The guide rods are suspended above the support platform. The guide rods are cantilevered to extend from a fixed end 714 at the rear wall to a distal end 716, the distal end 716 being spaced from the rear wall and supported in space by the rigidity of the guide rods. The guide rods may be secured in place through holes in the rear wall via fasteners (e.g., nuts, rivets, etc.), punch rivets, spot welds, etc. In the illustrated embodiment, the guide rods are arranged in two vertical columns 718. One of the guide bars in each column is aligned with a corresponding guide bar in the other column to define a pair of bars. Each pair of rods is associated with a different one of the modules in the stack of modules. Two vertical columns are disposed on opposite sides of a slot 720 defined through the back wall. The slot 720 may represent the slot 614 of the back wall 506 shown in fig. 12. The slots 720 allow air to flow through the rear wall. The guide rod may have a rigid composition, for example, comprising one or more metals. In an embodiment, the guide rod is threaded helically. The guide rods of the mounting system may be duplicates or copies of each other such that the guide rods have a common size, shape, composition, etc. Although the guide bars are arranged in two columns in the illustrated embodiment, in alternative embodiments, the guide bars may be arranged in a single column or at least three columns.

The lifting element 706 is a member mounted at or near the rear wall. The lifting elements are configured to mechanically engage (directly physically contact) the module during the installation process. More specifically, the lifting element is configured to at least partially support the weight of the module when the module reaches a fully loaded position relative to the frame. The lifting elements may also facilitate assembly of the electrical power delivery system by ensuring that the modules are aligned with corresponding components (e.g., the vertical bus bars 206, the electrical connectors, the sidewalls of the rack, the support members 512, etc.) coupled to the modules. Without the lifting elements, the module may not be properly aligned with these components.

In the illustrated embodiment, the lifting element is mechanically coupled to the back wall and spaced apart from the guide rods. For example, each lifting element in fig. 13 is separately and independently coupled to the back wall. The lifting element may be coupled to the back wall via fasteners (e.g., nuts, rivets, etc.), punch rivets, spot welds, etc. The lifting elements are optionally arranged in two vertical columns collinear with the column of guide rods. As with the guide rods, the lifting elements of different columns may be aligned in pairs. To support the module, the lifting element may have a rigid composition that may include one or more metals. In the illustrated embodiment, the lifting element extends from the front side of the rear wall by a length shorter than the guide rods. The lifting element shown in fig. 13 is also referred to herein as a pin.

Fig. 14 is a side cross-sectional view of a mounting system 700 showing a first module 722 of a stack of modules ready for installation, according to an embodiment. The first module 722 may represent the lowermost module 204A shown in fig. 2 and 10. The cross-section is taken along a plane extending through the guide rod 704 and one of the columns 718 of lifting elements 706, and through a portion of the housing 724 of the module 722. The housing 724 defines at least one channel 726, the channel 726 being configured to receive a corresponding one of the guide rods therein. In the illustrated embodiment shown in fig. 13 and 14, the housing may define two channels, each of the two channels configured to receive a different one of the two guide rods in a corresponding pair. Only one of the channels is shown in fig. 14. The channel not visible in fig. 14 receives therein a guide bar from the other column. The channels extend along the length of the module 722 between the rear side 728 and the front side 730 of the module 722. Each channel has a rear opening 732 at the rear side. The channel optionally extends completely from the posterior side to the anterior side, and includes an anterior opening 734 at the anterior side. Alternatively, the channel does not extend completely to the front side face, such that the front opening of the channel is located axially between the rear side face and the front side face.

In an embodiment, the module is configured to be loaded in a loading direction 736 relative to the rack 702 for mounting the module. The loading direction is toward the rear wall 708. The weight of the module may be supported, in whole or at least in part, by the support platform 710. For example, the bottom side 738 of the module is disposed on (e.g., directly engaged with) the top surface 740 of the support platform. The module may be passively moved in the loading direction by receiving an external force. For example, an operator may grasp a handle on the frame 742 of the module to push the module toward the back wall in the loading direction 736. Optionally, a machine (e.g., a robot) may be programmed to push the module. The bottom side of the module is slidable along the support platform toward the rear wall. For example, the force exerted on the module may be sufficient to exceed the resistance caused by static friction between the module and the top surface of the support platform. The mechanical support provided by the platform may reduce the amount of force required to load the module relative to an operator and/or machine to lift and carry the module in the loading direction. In a non-limiting example, the module may be relatively heavy for a person carrying, such as between 50 and 150 pounds (lb) (e.g., 22 to 68 kg). In the illustrated embodiment, the support platform projects outwardly away from the rear wall beyond the distal ends 716 of the guide rods 704, which allows the rear portion of the module to be placed on the support platform before the guide rods are received within the channels 726.

During assembly of the module stack, the rear portions of the modules may rest on the support platform before any necessary adjustments are made to the modules to align the channels with the corresponding guide rods. Once the channels are aligned with the guide rods, the module is slid over the support platform in the loading direction so that the guide rods enter the corresponding channels of the module. The rear opening 732 of the channel may define a sloped lead-in section 744 to reduce the risk of seizure (stubbing) between the distal end of the guide rod and the rear opening. For example, the diameter of each channel may taper conically inwardly (in a direction towards the front side) from the rear opening at the rear side along the inclined lead-in section.

The guide rods of the lowermost pair of guide rods are disposed at a designated height above the support platform and the channels of the module are disposed at a designated height above the bottom side of the module such that the guide rods can be received into the corresponding channels when the bottom side of the module is supported by the support platform. The interaction between the guide rods and the channels may guide the module towards the rear wall into proper alignment with the rack as the module moves in the loading direction. For example, the guide rods are oriented parallel to the loading direction. In an embodiment, the support platform supports all or at least most of the weight of the module during the initial stage of loading the module towards the rear wall. For example, the guide rods may not support any weight, or may support only a small percentage (e.g., less than 10%) of the weight when the module rests on the support platform.

Fig. 15 is a side cross-sectional view of a mounting system 700 showing a first module 722 in a first intermediate load position relative to a rack 702, according to an embodiment. In the illustrated embodiment, the module is disposed closer to the back wall 708 than in the initial position shown in fig. 14 due to being forced to slide along the support platform 710 in the loading direction 736. The module engages at least one of the lifting elements 706 before abutting the rear wall. As mentioned above, in the illustrated embodiment, the lifting elements 706 are pins mounted on the rear wall. The pins are arranged in pairs such that adjacent pairs are vertically spaced apart. The pin shown in fig. 15 of the splice module is a first pin 706A (e.g., a first lifting element). The other pin of the pin pair having the first pin is masked by the first pin and is therefore not visible in fig. 15.

The housing 724 of the module may define at least one receptacle (receptacle)746 along the rear side 728. The at least one receptacle may be spaced apart from the channel 726. For example, a middle portion 748 of the housing separates each jack from adjacent channels. Based on the arrangement of the pair of pins as shown in fig. 13, the module may define two receptacles at the rear side such that each of the receptacles receives a different pin of the pair of pins therein when the module reaches the pins. The guidance and alignment provided by guide rod 706 within channel 726 may enable the receptacle of the module to be aligned with a corresponding pin on the back wall to prevent jamming (or at least reduce the likelihood thereof).

In an embodiment, the module remains supported by the support platform upon initial physical contact with the pin. Thus, the module can be slid along the support platform in the loading direction from the position shown in fig. 14 to the position shown in fig. 15. Each channel 726 may have a diameter (e.g., even at its narrowest section) that is greater than the diameter of the corresponding guide rod 704 received therein to define an open interstitial region between the guide rod and the inner surface of the channel. In fig. 15, when the module is supported on the support platform, the guide rods are disposed within an upper region of the channel and define an open void area 750 within the channel below the guide rods.

In an embodiment, once the distal section 754 of each guide rod within the channel of the module is accessible through the front opening 734 of the channel, the fastener 752 may be coupled to the distal section. The distal sections extend to respective distal ends 716 of the guide rods. The fastener is releasably coupled to the guide bar to secure the module to the frame by preventing the module from moving relative to the frame in a direction opposite the loading direction. The fastener may exert a clamping force on the housing of the module in the loading direction. In an embodiment, the stem is helically threaded and the fastener is an internally threaded nut threadably coupled to the stem. The fastener may also include a washer sandwiched between the engaging surfaces of the nut and the housing. The nut and washer may apply a clamping force by applying a torque to the nut to move the nut axially relative to the guide bar toward the rear wall. Optionally, fasteners may also be used during installation to assist in moving the module from the position shown in FIG. 15 to a fully loaded position in which the module abuts the rear wall. In other embodiments, the fasteners may include or represent one or more of clips, posts, clamps, and the like.

Fig. 16 is an enlarged cross-sectional view of a portion of the mounting system 700 shown in fig. 15. Although the following description specifically identifies and describes elements shown in fig. 16, the description may apply to similar elements not visible in fig. 16. For example, fig. 16 may show one guide bar 704 and one pin 706 disposed within the same vertical column that interacts with module 722, and the description may also apply to an associated guide bar and associated pin in another vertical column (as shown in fig. 13). As the module approaches the rear wall 708, the pin 706 engages the module to define an angled contact interface 760 between the pin and the module. The angled contact interface passively lifts the module off the support platform 710 (shown in fig. 15) in response to additional movement of the module in the loading direction. For example, the angled contact interface is inclined or beveled transverse to the plane of the support platform. The angled contact interface converts lateral movement of the module in the loading direction (parallel to the plane of the support platform) into vertical movement of the module away from the support platform.

One or both of the pin and module housings 724 define a ramp surface that represents part of an angled contact interface. For example, in the illustrated embodiment, the pin has a ramped surface 762, the ramped surface 762 defining at least a portion of an angled contact interface. The ramp surface is defined along a tapered distal section 764 of the pin. The tapered distal section 764 may have a conical shape. As the module moves relative to the pins, contact surfaces 766 within receptacles 746 of the module slide along the ramp surfaces. The angle of the ramp surface converts lateral movement of the module into vertical movement away from the support platform.

The rear opening 768 of the receptacle at the rear side 728 of the housing may be countersunk to provide an enlarged lead-in area to prevent jamming on the pin. In the illustrated embodiment, the countersunk portion 770 has an angle of inclination that is greater than the angle of the ramp surface. As a result, the module will not be lifted by the pins until the ramped surfaces of the pins engage the inner edge of the module separating the countersunk portion from the main portion 772 of the socket. The inner edge represents the contact surface 766 of the module in an angled contact interface. For example, the inner edge contacts and slides along the ramped surface of the pin as the module moves in the loading direction.

In an alternative embodiment, the sloped surface along countersunk portion 770 may represent a contact surface in addition to the inner edge. For example, the ramped surface of the pin may contact and slide along the sloped surface of the countersink to provide the lift. In another alternative embodiment, the socket of the module does not define a countersunk portion, and the top surface of the socket at the rear opening represents the contact surface of the ramped surface of the engagement pin. In yet another alternative embodiment, the pin does not have a ramp surface, and the angled contact interface is provided by an inclined surface of a countersunk portion of the socket. For example, when a pin is received within a receptacle to lift the module, an edge of the pin may engage and slide along a sloped surface of the countersunk portion.

In the illustrated embodiment, the pin has an intermediate section 774 disposed axially between the rear wall and the tapered distal section. A surface 776 (e.g., a middle surface) of the middle section is between the ramp surface and the back wall. The intermediate surface has a uniform height (or distance) above the support platform along the length of the intermediate section. For example, the intermediate section may be a cylindrical portion having a central axis parallel to the plane of the support platform, and the intermediate surface is the outer surface of the cylinder facing away from the support platform. The ramp surface causes the module to gradually lift vertically away from the support platform with additional movement in the loading direction as the contact surface of the module engages and slides along the ramp surface. Once the contact surface of the module moves beyond the ramp surface, the contact surface engages and moves along the intermediate surface. Because the intermediate surface is parallel to the support platform, the rear end of the module can be maintained at a constant height above the support platform as the contact surface slides along the intermediate surface.

Thus, according to at least one embodiment, the mounting system is designed such that the module being loaded moves laterally parallel to the support platform during an initial loading phase in which the module is supported by the support platform. Then, during a second loading phase in which the modules are moved laterally and vertically, the modules are gradually lifted upwards away from the support platform. Finally, before engaging the rear wall of the rack, the intermediate surface module is again moved laterally parallel to the support platform. In an alternative embodiment, the pin does not have an intermediate section, and the ramp surface extends completely to the rear wall or rear end of the pin.

Fig. 17 is an enlarged cross-sectional view of a portion of mounting system 700 shown in fig. 15 and 16, showing module 722 during a second stage of loading, during which the module moves not only laterally, but also vertically, relative to frame 702. In the illustrated position, the contact surface 766 of the module within the receptacle 746 engages the ramp surface 762 of the pin 706 adjacent the intermediate surface 776. Due to the angled contact interface 760 between the contact surface of the module and the ramp surface of the pin, the module is lifted off the support platform 710 by the pin as the module moves in the loading direction toward the rear wall 708. In the illustrated embodiment, the bottom side 738 of the module is spaced apart from the top surface 740 of the support platform by a gap 778 (e.g., a spacing gap). This gap indicates that the module is not supported by the support platform in the illustrated position of the module. Additional evidence of vertical movement of the module relative to the frame is that guide rods 704 are positioned lower in channel 726 in fig. 17 relative to the pre-lift position shown in fig. 16. For example, the guide rod 704 is centered within the channel in fig. 17, but is off-center and near the top region of the channel in fig. 16.

In an embodiment, the module may include a pad 780 mounted to the rear side 728 of the housing 724. The pad 780 may be the plenum pad 338 shown in FIG. 5. The gasket is compressible and may be constructed of an elastomeric material such as silicone, neoprene, rubber (e.g., natural or synthetic), etc. The gasket may be compressed between the rear side and the rear wall of the module when the module is in the fully loaded position relative to the chassis. In the compressed state, the cushion can dampen vibrations. In fig. 17, the gasket is spaced from the rear wall. For example, to prevent damage and stress to the gasket due to shear forces, the gasket may not engage the back wall while the module is moving vertically. The presence of the intermediate surface 776 ensures that the module only moves laterally (e.g., perpendicular to the plane of the rear wall 708) when the gasket is in contact with the rear wall.

Fig. 18 is a cross-sectional view of the mounting system 700 of fig. 15-17, showing the module 722 in a fully loaded position relative to the rack 702, according to an embodiment. In the fully loaded position, the module abuts the rear wall 708 of the rack. The pad 780 shown in fig. 17 is not visible in fig. 18 because the pad is compressed between the back side 728 and the back wall of the module. The module is completely separated from the support platform 710 by a gap 778. In the illustrated embodiment, no portion of the module or support platform bridges the gap, such that the entire module is spaced from the support platform. The weight of the module is supported by the back wall, the pins 706 in the receptacles 746 and/or the guide rods 704 in the channels 726.

The module may reach the fully loaded position when the module is at a right angle (squaring) against the back wall such that the channel 726 is oriented approximately perpendicular to the plane of the back wall (e.g., within a specified tolerance margin, such as within 1 °, 3 °, or 5 °). The module can be moved from the position shown in fig. 17 to the fully loaded position shown in fig. 18 by tightening the fasteners 752 to apply a clamping force on the housing 724 in the loading direction that moves the module. In embodiments where the fastener is a threaded nut, the nut may be torqued to rotate the nut such that the fastener will push the shoulder 782 of the housing at or near the front side 730 toward the rear wall. The normal force exerted by the rear wall in a direction opposite to the loading direction may square the module against the rear wall in reaction to the clamping force. In an alternative embodiment, the module may be moved to the fully loaded position by manually pushing the module in the loading direction until the module is at a right angle against the rear wall, and then tightening the fasteners to secure the module in the fully loaded position. The entire weight of the module may be supported by a combination of forces including the clamping force exerted by the fastener on the housing, the normal force exerted by the back wall on the housing, and the force exerted by the pin on the receptacle of the housing.

Fig. 19 is a side cross-sectional view of a mounting system 700 according to an embodiment, showing a first module 722 in a fully loaded position and a second module 802 ready for installation. The second module 802 may represent the second module 204B from the lowermost level in the stack 202 shown in fig. 2 and 10. The second module may include a housing 804, which may have the same or at least a similar form factor as housing 724 of first module 722. For example, the housing 804 defines two channels 806 in which a corresponding pair of guide rods 704 are received, and defines two receptacles 808 in which a corresponding pair of pins 706 are received. The second module may also include pads 814 mounted on the back side 816 of the housing, similar to the pads 780 on the first module (shown in fig. 17). The second module 802 is disposed above the first module 722 in a stack such that the first module is between the second module and the support platform 710.

The second module may be supported by the first module during an initial stage of loading. For example, bottom side 810 of the second module may be placed in physical contact on top side 784 of the first module. The first module functions similarly to the support platform in that the first module can support all or at least a majority of the weight of the second module. In the illustrated embodiment, the second module is supported on the frame 742 of the first module. The shelf is coplanar with the top side of the first module and/or defines an extension of the top side. The second module is then moved by an operator or machine in the loading direction toward the rear wall 708 so that the second module slides along the top side of the first module. The installation of the second module is similar to the installation of the first module. For example, once the pin engages the second module at the angled contact interface, the second module begins to lift off the first module with additional movement of the second module in the loading direction.

Fig. 20 is a cross-sectional view of a mounting system 700 showing both a first module 722 and a second module 802 in a fully loaded position relative to a rack 702, according to an embodiment. When the second module reaches the fully loaded position against the back wall 708, the second module may be secured in the fully loaded position via fasteners 812. As shown in fig. 20, the second module in the fully loaded position is supported by the pins 706 in the receptacles 808, the clamping force exerted on the housing 804 by the fasteners 812, and/or the normal force exerted on the rear side 816 of the housing by the rear wall. The cushion 814 may be compressed between the back wall and the rear side to provide vibration damping. The second module is spaced apart from the underlying first module by a gap 820 defined between the bottom side 810 of the second module and the top side 784 of the first module. Optionally, when the second module is mounted to the rack in the fully loaded position, the weight of the second module is not supported at all by the first module.

Additional modules of the module stack may be mounted to the chassis in the same manner as the second module 802. A third module immediately above the second module (e.g., module 204C shown in fig. 2 and 10) may be loaded, for example, by sliding the third module along the top side 822 of the second module in the loading direction until the third module is lifted off the second module by engagement with the pins 706 of a third pair of pins from the bottom-most on the rack. In this way, the module stack is assembled one after the other from the bottom.

Fig. 21 is a side view of mounting system 700 showing four modules mounted to rack 702 in a stack of modules 828, according to an embodiment. These four modules include a first module 722, a second module 802, a third module 830 above the second module, and a fourth module 832 above the third module 830. The fourth module is the uppermost module in the stack. All four modules are mounted in a fully loaded position relative to the rack. In an embodiment, when the stack of modules is fully assembled as shown in fig. 21, each module is spaced apart from an adjacent module in the stack (and from the support platform 710) by a spacing gap. For example, a first module is separated from support platform 710 by gap 778 and separated from an overlying second module by gap 820. The third module is separated from the second module below by a gap 834 and from the fourth module above by a gap 836.

The side view shown in fig. 21 illustrates several aspects of the mounting system 700. For example, the spacing gap between modules provides electrical, mechanical, and thermal isolation between modules. The module may have internal electrical components that generate heat. The spacing gap allows cooling fluid to flow between the modules so that the cooling fluid, e.g., air, liquid, or another type of gas, can absorb and dissipate heat from the system. The gap may also serve to prevent or at least limit the diffusion of thermal energy between the modules. For example, if one of the modules experiences a fire and/or thermal runaway, the gap may limit the spread of the fire and/or thermal runaway to adjacent modules, which may reduce the amount of damage and losses caused by the fire and/or thermal runaway. The gap may also allow for the presence of air or another dielectric material that electrically insulates the modules from one another. The electrical insulation may reduce the effects of electromagnetic interference between the modules, which may improve the performance of the internal electronic components of the modules. The mechanical isolation provided by the spacing gap enables any module in the stack to be individually and independently unloaded with similar and limited effort. For example, if a failure of the first module 722 is suspected, the operator may remove the first module 722 from the stack to perform maintenance without removing the upper three modules. Without a clearance gap above the first module, the weight of the upper three modules may be applied on top of the first module. In such a design without gaps, it may be necessary to remove all three modules above from the stack to access the desired first module.

The size of the gaps between the modules may be selected and/or customized to provide a desired amount of thermal and/or electrical isolation between the modules. For example, the height of the gap may be increased to provide additional electrical isolation between modules. In another example, if there is a significant risk of fire, the height of the gap may be increased to reduce the likelihood of secondary damage to other modules in the stack. In the illustrated embodiment, the gaps all have the same size as one another, but in alternative embodiments, at least some of the gaps may have different sizes from one another. For example, if the fourth module 832 is more fire-hazard, is a larger electromagnetic interference producer, and/or is more sensitive to electromagnetic interference than one or more of the other modules in the stack, the gap 836 between the fourth module 832 and the third module 830 may be sized larger than the gaps between the other modules to provide increased isolation. The size of the gap may be controlled by the positioning of the lifting elements (e.g., pins) and guide rods on the back wall 708.

Optionally, one or more inserts may be installed into the gap after the module is installed to the rack. The inserts may include or represent vibration dampening inserts for reducing relative movement between modules, cooling inserts for providing active and/or passive cooling, fire suppression inserts, and the like. The insert may have various forms including a pad, foam, sheet, and the like. Optionally, the insert may occupy only a portion of the gap to maintain a passage for air or the like. Vibration damping may also be achieved by gaskets (e.g., gaskets 780, 814) mounted between the rear wall and the rear side of the module and/or rigid support members 512 shown in fig. 10, which rigid support members 512 mechanically couple the modules together at or near the front end of the modules.

In an alternative embodiment, instead of sliding each of the modules on the support platform or on the module below when loading and unloading the modules, the modules may be equipped with rolling elements along their respective top or bottom sides. The rolling elements may comprise wheels, cylindrical rollers, or the like. The presence of the rolling elements reduces the resistance caused by friction when loading and unloading the modules. In an embodiment, the module is fully lifted off the support platform and/or the module below when the fully loaded position is reached, even with the rolling elements. The elevation defines a spacing gap. For example, an angled contact interface may lift the module to the point where the rolling elements are separated from the contact surface.

Fig. 22 is a cross-sectional view of the mounting system 700 showing a first intermediate loading stage of the first module 722, according to a first alternative embodiment. The first module is supported by a support platform 710. In the illustrated embodiment, the lifting elements of the frame 702 are mounted on the guide rods 704 rather than being spaced apart from the guide rods and mounted directly to the rear wall 708. For example, the lifting element may be a washer 902 having a conical shape. The conical washer may annularly surround the guide rod. A conical washer is positioned at least proximate to the back wall and optionally may be disposed in contact with the back wall. The outer surface of the gasket is sloped to define a ramp surface 904, the ramp surface 904 representing a portion of the angled contact interface that lifts the module off of the support platform. For example, as the module moves in the loading direction toward the rear wall, the conical washer eventually engages the angled contact surface 905 along the lead-in section 744 of the channel 726 (at the rear opening 732). The ramp surface 904 of the conical washer and the contact surface 905 of the lead-in section may have complementary angles and may define an angled contact interface.

Fig. 23 is a cross-sectional view of the mounting system 700 according to the alternative embodiment shown in fig. 22, illustrating a second intermediate loading stage of the first module 722. In the illustrated embodiment, the fastener 906 is mounted on the distal section 754 of the guide bar 704 before the module is moved to the fully loaded position. In the illustrated embodiment, the fastener 906 is a kit including a conical washer 908 and a threaded nut 910. Conical washer 908 may be a replica or a copy of conical washer 902. The conical washer 902 near the back wall may be referred to as a back lift element or back conical washer, and the conical washer 908 engaging the nut 910 may be referred to as a front lift element or front conical washer. The forward conical washer may mirror the aft conical washer. The forward conical washer is axially disposed between the nut and the rearward conical washer. Although shown as two separate elements, the fastener may in alternative embodiments be a single, one-piece, unitary member that combines the functions of a conical washer and a threaded nut (e.g., a threaded conical nut). The ramp surface 912 of the forward conical washer may engage the angled contact surface 914 at the forward opening 734 of the channel 726. In an embodiment, the module is moved from the position shown in fig. 22 and 23 to the fully loaded position by applying a clamping force on the module using the fastener 906.

Fig. 24 is a cross-sectional view of the mounting system 700 according to the alternative embodiment shown in fig. 22 and 23, showing the first module 722 in a fully loaded position. Applying torque on the nut 910 rotates the nut and moves both the nut and the front conical washer 908 relative to the guide rods 704 toward the rear wall 708. As a result, the ramp surface 912 of the forward conical washer wedges under the contact surface 914 of the module, which moves the module further in the loading direction and also helps lift the front end 916 of the module off of the support platform 710. For example, the combined clamping force exerted by the fastener 906 on the module and the normal force exerted by the back wall on the back side of the module may provide a majority of the lift of the front end of the module. Additional movement of the module in the loading direction causes the rear conical washer 902 to lift the rear end 918 of the module off the support platform. The end result is a spacing gap 778 between the module and the support platform. The conical washer optionally may include a compressible material, such as a rubber coating, that provides vibration damping. The additional module above the first module is mounted in a similar manner to the first module.

In another alternative embodiment, the lifting element of the mounting system may include both the pin shown in fig. 13-20 and the forward conical washer shown in fig. 22-24. For example, the fastener 752 shown in FIG. 15 may include a conical washer similar to the forward conical washer 908.

Fig. 25 is a cross-sectional view of a mounting system 700 according to a second alternative embodiment, showing an intermediate stage of loading of a first module 722. In the intermediate loading stage shown, the first module is supported by the support platform 710. Fig. 26 is a cross-sectional view of the mounting system 700 according to the alternative embodiment shown in fig. 25, showing the first module 722 in a fully loaded position. In the illustrated embodiment, the lifting elements are wedge-shaped members. For example, the support platform 710 includes corresponding wedge members 950 (only one of which is visible in the illustrated cross-section). Wedge member 950 is disposed at least proximate to rear wall 708. For example, in the illustrated embodiment, the wedge member is spaced from the rear wall, and the wedge member optionally may contact the rear wall. The wedge-shaped element may comprise a ramp surface 952, which ramp surface 952 is inclined transversely to the plane of (the remainder of) the support platform.

As shown in fig. 25, the bottom side 738 of the module slides along the support platform as the module moves toward the rear wall in the loading direction. Finally, the corners 954 of the module between the bottom and rear sides 728 engage the ramp surfaces of the wedge members that define an angled contact interface between the lifting element and the module. Referring now to fig. 26, additional movement of the module causes the wedge members to passively elevate the module above the plane of the remainder of the support platform. Fasteners 956 coupled to the guide rods 704 provide a clamping force that secures the module in constant engagement with the rear wall, allowing the front end 916 of the module to hang above the support platform to define the spacing gap 958. While the rear end 918 of the module remains in contact with the support platform via the wedge members, a substantial portion of the bottom side of the module is spaced from the support platform to enable a gap to be formed.

In the illustrated embodiment, the first module may include a wedge member 960 that extends beyond the top side 784. The wedge members of the first module may have the same configuration or at least a similar configuration (e.g., size and shape) as the wedge members 950 of the support platform. The wedge members of the first module passively lift the second module 802 off the top side of the first module when the second module is loaded into the module stack.

Fig. 27 is a perspective view of a portion of the electrical power delivery system 200 shown in fig. 2. The illustrated portion of the electrical power delivery system shows an electrical energy storage device 208, which in the illustrated embodiment, electrical energy storage device 208 is a capacitor. The electrical power delivery system is oriented with respect to a lateral axis 1001, a height axis 1002, and a longitudinal axis 1003. The

axes

1001 and 1003 are perpendicular to each other. The axis 1001-1003 need not have any particular orientation with respect to gravity, however, in at least one embodiment, the height axis 1002 extends in a vertical direction parallel to gravity.

The capacitors are mechanically and electrically connected to the conductive bus bar (or conductive plane)206 and collectively extend from the second side 220 of the bus bar facing away from the module stack 202. The capacitors may be cylindrical and extend along respective central axes 222 from respective connection ends 1006 to respective distal ends 1008 opposite connection ends 1006. The connection terminals are disposed at the bus bars and are electrically and mechanically connected to the bus bars. The distal end is spaced from the bus bar. Thus, the capacitor is cantilevered from the bus bar. As described above, the central axis of the capacitor may be perpendicular to the plane 214 of the bus bar. Plane 214 may be oriented parallel to height axis 1002. The capacitors may extend laterally from the bus bars such that the central axis 222 is parallel to the lateral axis 1001.

In one or more embodiments, the electrical power delivery system may include at least one support structure 1004 that supports portions of capacitors and/or other electrical energy storage devices that are spaced apart from the electrically conductive bus bars. The support structure is spaced apart from the conductive bus bar. The support structure may engage a portion of the capacitor disposed between the connection end and the distal end to provide structural support for the capacitor. The support structure engages and at least partially surrounds each capacitor in the array. In the illustrated embodiment, the electrical power delivery system may include two support structures. Each of the support structures engages and at least partially surrounds four capacitors in a different one of two adjacent columns of capacitors. In alternative embodiments, the electrical power delivery system may have a different number of support structures than the two shown in FIG. 27.

The support structure may support a load to reduce a force applied at the connection ends of the capacitors connected to the bus bars. For example, the load supported by the support structure may comprise a portion of the weight of the capacitor. In a non-limiting example, each capacitor may weigh at least 5 pounds, for example 10 pounds, and thus the structural support provided by the support structure at a location spaced from the bus bar substantially reduces (or eliminates) the torsional forces applied at the connection end due to the length and weight of the capacitor. The load supported by the support structure may also include forces resulting from travel of a vehicle in which the electrical power delivery system is disposed. For example, during movement and other operation of the vehicle, vibrations, accelerations, and impact forces (e.g., from uneven terrain, etc.) may be exerted on the electrical power delivery system. The support structure may inhibit or at least limit movement of the capacitor relative to the bus bars and other components of the electrical power delivery system due to vibration, acceleration, and/or impact forces during vehicle travel. The support structure may also absorb and dissipate such forces to reduce the amount of force exerted on the capacitor relative to when the electrical energy storage device is directly connected to the rack. Reducing the magnitude of the force exerted on the capacitor may improve the operating performance and/or increase the operating life of the capacitor, as high forces may damage the capacitor or the connector between the capacitor and the bus bar.

In one or more embodiments, the support structure mechanically supports the corresponding capacitors along at least two

support directions

1010, 1012 that are orthogonal to each other. For example, the first support direction 1010 shown in fig. 27 is directed vertically upward parallel to the height axis 1002 to indicate that the support structure supports the weight of the capacitor (which is directed downward along the height axis 1002 due to gravity). The second support direction 1012 shown in fig. 27 is directed parallel to the longitudinal or depth axis 1003 and indicates that the support structure limits movement of the capacitor along the longitudinal axis 1003 due to vibration, acceleration, and/or impact forces. Fig. 27 also shows a third support direction 1014 that is parallel to and opposite the first support direction 1010 along the height axis 1002. Thus, the support structure limits the upward movement of the capacitor due to vibration, acceleration, and/or impact forces. The third support direction 1014 is orthogonal to the second support direction 1012. Although not indicated in the illustrated embodiment, the support structure may also support the capacitors in a fourth support direction that is parallel to the second support direction 1012 and opposite the second support direction 1012 along the longitudinal axis 1003 (and orthogonal to the first support direction 1010 and the third support direction 1014). Thus, the structural support supports each of the capacitors in at least one vertical direction parallel to the height axis and at least one longitudinal direction parallel to the longitudinal (or depth) axis (which is orthogonal to both the height axis and the lateral axis). The

support directions

1010, 1012, 1014 provided by the support structures are in a common plane 1016. The plane 1016 is parallel to and spaced from the plane 214 of the bus bar. Optionally, in addition to or instead of the support directions shown in FIG. 27, the support structure supports the capacitor in at least two orthogonal support directions in plane 1016 that are not parallel to

axis

1001 and 1003.

The support structure may be secured to a frame 504 of the electrical power delivery system, a housing 600 (shown in fig. 11), or another component on the vehicle. In the illustrated embodiment, the support structure is secured to a beam (or arm) 1018 of the gantry. By rigidly tying the support structure to the frame, the beam can mechanically support the support structure relative to the frame. Mechanically securing the support structure to the frame reduces relative movement between the support structure (and the capacitor) and the frame when the electrical power delivery system is exposed to forces caused by vibration, acceleration, and/or shock. In the illustrated embodiment, the beam is disposed above a top portion 1020 of the support structure, and the support structure may be coupled to the beam via fasteners, adhesives, or the like. The support structure may be fixed to the frame separately from the bus bars. For example, the support structure is mounted to a beam of the rack at a location spaced from the bus bar. In alternative embodiments, the support structure may be coupled to the frame at one or more other locations (e.g., at the bottom 1022 of the support structure or along the sides of the support structure) in addition to or in lieu of the top.

Fig. 28 is a side view of the electrical power delivery system 200, showing two support structures 1004 according to the embodiment shown in fig. 27. In the illustrated embodiment, the support structure surrounds at least a majority of the perimeter of each of the capacitors 208 to support the capacitors in multiple support directions. The capacitor may be cylindrical with a circular perimeter or circumference. The support structure in fig. 28 surrounds almost the entire circumference of each capacitor (if not the entire circumference) such that the support structure supports the capacitors in a series of radially extending support directions 1024. At least some of the radially extending support directions 1024 are orthogonal to each other.

In the illustrated embodiment, each support structure is an assembly that may include a first housing member 1030 and a second housing member 1032 coupled together around the capacitors to support the capacitors. The design of the support structure may be referred to as a clamshell design. The first housing member 1030 has an inner side 1034 and defines a plurality of concave recesses 1036 along the inner side. The concave recesses are spaced along a height of the first case member. Likewise, the second housing member 1032 of each support structure has an inner side 1038 and defines a plurality of concave recesses 1040 along the inner side, the concave recesses 1040 being spaced apart along the height of the second housing member.

The support structure is shown in an assembled state in fig. 28. In the assembled state, the inner side faces 1034, 1038 of the first and second housing members face toward each other. The capacitors are received in corresponding

female recesses

1036, 1040 of the housing members. For example, a given capacitor 208A is received within one of the

concave recesses

1036A and 1040A of the first housing member and the second housing member. The concave groove of the first housing member surrounds the first perimeter section of the capacitor and the concave groove of the second housing member surrounds the second perimeter section of the capacitor. The second peripheral section may be circumferentially spaced apart from the first peripheral section such that there is no overlap between the first shell member and the second shell member. The concave recesses of the first and second case members engage the outer surface of the capacitor to support the capacitor in a radially extending support direction.

The seam 1042 may be defined between the inner sides of the first and second shell members along a portion 1044 of the shell members that interfaces with the concave recess when the first shell member is coupled to the second shell member. For example, some portions 1044 are disposed between two concave grooves and other portions 1044 are disposed at the top 1020 and bottom 1022 of the support structure. Optionally, the inner side faces may be spaced apart at the seam to define a narrow gap between the two shell components. Alternatively, the inner side faces of the shell parts may abut against each other at the seam.

In the illustrated embodiment, each of the two support structures has a vertical orientation such that the support structures are parallel to each other and elongated parallel to a height axis 1002 shown in fig. 27. In alternative embodiments, the support structure may have a different orientation, such as a longitudinal orientation parallel to the longitudinal axis 1003 in fig. 27. The longitudinal orientation may be orthogonal to the vertical orientation shown. For example, the electrical power delivery system may include four longitudinally extending support structures, wherein each support structure surrounds two capacitors, rather than the two vertically extending support structures shown in the illustrated embodiment.

Fig. 29 is a perspective view of a portion of the first housing member 1030 of one of the support structures 1004 shown in fig. 27 and 28, according to an embodiment. Fig. 30 is a perspective view of a portion of the second case member 1032 of the same support structure. The first case member 1030 and the second case member 1032 may represent portions of either of two support structures that support the capacitor array as shown in fig. 27 and 28. The illustrated portions of the first housing member 1030 and the second housing member 1032 depict the ends of the support structure, such as the top 1020.

In an embodiment, the first housing member may include a stem 1050 extending from an inner side 1034 thereof. For example, the lever is mounted to the first housing member at a portion 1044 of the first housing member that borders the concave recess 1036. The rod may be at least partially embedded within the material of the first housing member. For example, the first shell member may be at least partially constructed of a composite material, a plastic material, or the like. The rods may be embedded within the material by securing the ends of each rod into holes in the material via an adhesive, epoxy, or the like, or may be embedded in situ during formation of the first shell member, such as by a molding process or the like. The rod may include a metallic material and a fastener. In an embodiment, the rod has a helical thread that can receive a threaded nut or another threaded fastener. The rods extend from the inner side surface in a parallel orientation. Although two rods are shown in the illustrated portion of the first housing section, in other embodiments, the entire first housing section may include more than two rods. The lever may be used to couple the first housing member to the second housing member. In other embodiments, other fasteners may be used, such as clips and quick connects.

As shown in fig. 30, the second housing member defines an aperture 1052 along its inner side surface 1038. Each aperture is sized and shaped to receive a single rod of the first housing member therein to couple the first and second housings together. The diameter of the aperture may be slightly larger than the diameter of the rod to allow the rod to be received within the aperture without jamming or otherwise restricting the coupling, while also providing alignment and guidance during the coupling operation. For example, the engagement between the rod and the inner surface of the aperture may provide a track that guides the coupling between the two housing members as they move toward each other and toward the capacitor therebetween. The aperture is positioned in alignment with the stem such that the aperture is located at a portion 1044 of the second housing member bordering the concave groove 1040. The aperture optionally extends completely through the entire width of the second housing member from the inner side 1038 of the second housing member to the outer side 1054 of the second housing member opposite the inner side. Optionally, the rods may protrude from the first housing member a distance greater than the width of the second housing member such that when the housing members are coupled together, the distal tip 1056 of each rod eventually exits the aperture and protrudes beyond the outer side of the second housing member.

In one or more embodiments, the first and second shell members include a compressible liner 1060 within the respective

concave recesses

1036, 1040. The compressible liner 1060 may engage the outer surface of the capacitor when the shell members are coupled together. The compressible liner is attached along the respective curved inner surfaces 1062 of the shell members that define the concave recess. The liner may be attached to the inner surface via an adhesive, fasteners, or the like. In an embodiment, the compressible liner comprises a different material than the body of the shell member. For example, the compressible liner may be less rigid and more flexible and compressible than the body of the shell member. Optionally, the liner may comprise or represent a foam or foam-like material, such as silicone foam or the like. The compressible liner can reduce and/or more evenly distribute compressive forces exerted on the capacitor as the first and second housing members are moved toward the capacitor to engage and surround the capacitor during the coupling process. For example, the liner may be compressed by different amounts at different locations, if desired, to make the clamping force applied to the capacitor more uniform. Compression of the liner during coupling may also provide the inherent benefit of self-centering of the support structure on the capacitor.

Fig. 31 illustrates a portion of one of the support structures 1004 shown in fig. 27-30 in a partially assembled state, in accordance with an embodiment. To assemble the support structure, the first and

second housing members

1030, 1032 are arranged along opposite sides of the corresponding capacitor 208 and aligned with each other such that the rods 1050 can be received into the corresponding apertures 1052. The case members are pushed toward each other and toward the capacitor therebetween. In an embodiment, both the first case member and the second case member are movable relative to the capacitor. The shell members move toward each other along the coupling axis 1066. Engagement of the rod within the aperture guides movement along the coupling axis and maintains alignment of the shell members. In the partially assembled state shown in fig. 31, the compression liner 1060 has just begun to engage the outer surface 1068 of the capacitor.

Fig. 32 illustrates a portion of the support structure 1004 of fig. 31 in a fully assembled state, in accordance with an embodiment. In one or more embodiments, once the distal tip 1056 of the rod 1050 protrudes from the aperture along the lateral side 1054 of the second housing member 1032, the fastener 1070 is coupled to the distal tip to secure the first and second housings together. In an embodiment, fastener 1070 is a nut that is threadably coupled to a threaded rod. Providing a rotational torque on the nut to rotate the nut on the rod may exert a clamping force that pulls the two housing components together along the coupling axis 1066 (shown in fig. 31). The clamping force applied by tightening the nut may effect self-centering of the support structure around the capacitor. For example, if there is a larger gap between the first case member and the capacitor than between the second case member and the capacitor, the clamping force may move the first case member a greater distance toward the capacitor and the second case member than the second case member moves to provide self-centering. The compressive liner 1060 can distribute the clamping force to provide a relatively uniform compressive force around the perimeter of the capacitor.

In an embodiment, after coupling the first and second housing members together to assemble the support structure on the capacitor, the assembled support structure is then secured to the frame 504. Optionally, the support structure may be secured to the frame via mounting brackets 1072, the mounting brackets 1072 coupling a top 1020 of the support structure to a beam 1018 of the frame (shown in fig. 27). Prior to fixing the support structure to the frame, the support structure may be assembled such that the two shell parts can move freely along the coupling axis during the coupling process.

Fig. 33 shows a support structure 1100 for mechanically supporting a plurality of electrical energy storage devices (e.g., capacitors) of an electrical power delivery system, according to a first alternative embodiment. Two of the support structures 1100 may be used in place of the two support structures 1004 shown in fig. 27-32. The support structure 1100 has a unitary, unitary (e.g., one-piece) body 1102, the body 1102 defining a plurality of openings 1104 therethrough. The opening extends completely through the thickness of the body. The openings are spaced along a surface region of the support structure. Each opening is sized and positioned to receive a single capacitor therein. In the illustrated embodiment, the support structure has four openings arranged in different quadrants of the support structure.

To mount the support structure on the capacitors (or other energy storage devices) extending from the bus bar, the support structure is moved relative to the capacitors in the mounting direction. The mounting direction is oriented along the lateral axis 1001 shown in fig. 27 toward the bus bar 206 such that the distal end 1008 is the first portion of the capacitor received through the opening of the support structure. Due to the quadrilateral arrangement of the four openings, the support structure can be mounted on the upper group of four capacitors or the lower group of four capacitors shown in fig. 27. Another support structure, which is a replica of the illustrated structure, may be mounted to another set of four capacitors to mechanically support all eight capacitors in the array. Alternatively, the support structure 1100 may be redesigned to define eight openings that are sized and positioned to mechanically support all eight capacitors using a single support structure.

In the illustrated embodiment, the openings are not closed shapes (e.g., closed circles), but are open at corners 1106 of the support structure. The open corners may enable the body of the support structure to at least partially deflect or bend when the support structure is loaded onto the capacitor, which may provide alignment and/or self-centering of the support structure relative to the capacitor. The support structure optionally may have a compressible liner (not shown) along the inner surface 1108 of the body defining the opening. Similar to support structure 1004, support structure 1100 can engage and at least partially surround a capacitor and mechanically support the capacitor along at least two support directions that are orthogonal to each other.

Fig. 34 shows a support structure 1200 for mechanically supporting a plurality of electrical energy storage devices (e.g., capacitors) of an electrical power delivery system, according to a second alternative embodiment. In the illustrated embodiment, the support structure has a unitary, unitary (e.g., one-piece) body 1202, the body 1202 defining a plurality of recesses 1204 along a first side 1206 of the body. The depressions are positioned in a quadrilateral arrangement similar to the openings 1104 of the support structure 1100 shown in fig. 33. The recess optionally does not extend completely through the thickness of the body. In contrast, a depression resembles a meteorite crater or a carious cavity (cavity). The recesses are positioned and sized such that each recess receives a distal end 1008 (shown in fig. 27) of a different capacitor therein when the support structure is moved in the mounting direction toward the bus bar to mount the support structure on the capacitor. The recess surrounds a distal end of the (cup) capacitor. The body of the support structure may be at least partially compressible or deflectable to cushion and/or absorb forces. For example, the body may comprise a compressible foam.

Similar to support structure 1100, two of support structures 1200 may be used to mechanically support all eight capacitors. Alternatively, the support structure 1200 may be redesigned to define eight recesses sized and positioned for mechanically supporting all eight capacitors using a single support structure. Similar to support

structures

1004 and 1100, support structure 1200 can engage and at least partially surround a capacitor and mechanically support the capacitor along at least two support directions that are orthogonal to each other.

Fig. 35 illustrates a support structure 1300 for mechanically supporting a plurality of electrical energy storage devices (e.g., capacitors) 208 of an electrical power delivery system, according to a third alternative embodiment. The support structure 1300 may include a rigid body 1302 and a plurality of collars 1304 tethered to the rigid body 1302. The rigid body may be a post attached to the frame or may represent a portion of the frame. Each collar is a ferrule that engages and wraps around a different capacitor. The collar is tethered to the rigid body via a strap 1306. Similar to support

structures

1004, 1100, and 1200, support structure 1300 can mechanically support a capacitor along at least two support directions that are orthogonal to each other.

In one or more embodiments, the particular type, material, and/or dimensions of the support structure(s) used to mechanically support the electrical energy storage device may be selected based on the intended use of the electrical power delivery system. For example, if the electrical power delivery system is to be installed onboard an off-highway vehicle that is subject to significant vibration and/or impact forces due to traveling over uneven terrain or other operations, the type of support structure or its materials and dimensions may be selected to provide a desired amount of support to withstand such vibration and/or impact without damaging or degrading the energy storage device. In a non-limiting example, the two-piece clamshell design of support structure 1004 shown in fig. 27-32 may provide more support than the unitary design of support structure 1100 shown in fig. 33. Based on this assumption, the support structure 1004 may be selected for more severe use applications where greater forces are expected to be exerted on the electrical power delivery system, and the support structure 1100 may be selected for more moderate use applications with lower expected forces on the electrical power delivery system. In addition to selecting the type of support structure, the material, dimensions, and/or mounting to the frame of the support structure may be customized or selected according to the severity of the intended use. For example, the type and/or size of the compressible liner within the support structure may have a selected level of compliance (or other property) designed to absorb and dissipate a desired amount of force.

In one or more embodiments, an electrical power delivery system is provided that includes a stack of modules, a conductive bus bar, and one or more energy storage devices. The module stack includes a plurality of modules stacked side-by-side along a stack axis. Each module has a respective housing and internal electrical components within the housing. The conductive bus bars are oriented along a plane parallel to the stack axis. Bus bars are mounted along the sides of the stack of modules and are electrically connected to one or more of the modules. The one or more energy storage devices are electrically connected to the bus bar and extend from a side of the bus bar facing away from the module stack such that the bus bar is disposed between the one or more energy storage devices and the module stack.

Optionally, the internal electrical components of at least two modules of the stack of modules have the same configuration. The internal electrical components of at least one module in the stack of modules are different from the internal electrical components of another module in the stack of modules.

Optionally, the housings of the modules of the module stack have the same form factor.

Optionally, a module of the module stack comprises a rectifier module between two inverter modules. The rectifier module is configured to distribute current to the two inverter modules via the bus bars. Optionally, the rectifier module is electrically connected to an alternator that supplies current to the rectifier module, and the two inverter modules are electrically connected to different corresponding motors to supply current for powering the motors.

Optionally, the modules of the module stack comprise at least one inverter module, at least one rectifier module and at least one chopper module. Optionally, a first chopper module of the at least one chopper module is disposed at an end of the stack of modules.

Optionally, the internal electrical components within the housing of the module include one or more of a transistor, a diode, or an inductor.

Optionally, the one or more energy storage devices comprise an array of capacitors mounted to the bus bars. Each capacitor in the array extends from the bus bar along a respective central axis. The central axes of the capacitors are parallel to each other and perpendicular to both the stack axis and the plane of the bus-bar row.

Optionally, the electrical power delivery system further comprises a housing. The stack of modules, the bus bar, and the one or more energy storage devices are collectively housed within the housing.

Optionally, the electrical power delivery system further comprises a frame. The modules of the module stack are mounted to and supported by the frame such that adjacent modules of the module stack are spaced apart from each other by a spacing gap.

In one or more embodiments, an electrical power delivery system is provided that includes a stack of modules and a bus bar. The module stack includes a plurality of modules stacked side-by-side along a stack axis. Each module has a respective housing and internal electrical components within the housing. Bus bars are mounted along the sides of the stack of modules and are electrically connected to one or more of the modules. The bus bar includes a laminated assembly of a plurality of conductor planes. The modules of the module stack comprise a rectifier module between two inverter modules. The rectifier module is configured to distribute current to the two inverter modules via the bus bars. The internal electrical components of the rectifier module are configured to convert the current received from the power source from an alternating current form to a direct current form. The internal electrical components of the two inverter modules are configured to convert the current received from the rectifier modules from a direct current form to an alternating current form.

Optionally, the bus bars are oriented along a plane parallel to the stack axis.

Optionally, the rectifier module is electrically connected to an alternator, which supplies current to the rectifier module. The two inverter modules are electrically connected to different corresponding motors to supply current for powering the motors.

Optionally, the modules of the module stack further comprise a chopper module disposed at an end of the module stack.

Optionally, the electrical power delivery system further comprises an array of capacitors mounted to the bus bar and extending from a side of the bus bar facing away from the module stack such that the bus bar is disposed between the module stack and the array of capacitors. Each capacitor in the array extends along a respective central axis perpendicular to the stack axis.

In one or more embodiments, an electrical power delivery system is provided that includes a stack of modules and a conductive bus bar. The module stack includes a plurality of modules stacked side-by-side along a stack axis. Each module has a respective housing and internal electrical components within the housing. The housings of the modules of the module stack have the same form factor. The conductive bus bars are mounted along the sides of the stack of modules and are electrically connected to one or more of the modules. The internal electrical components of at least two modules of the module stack have the same configuration. The internal electrical components of at least one module in the stack of modules are different from the internal electrical components of another module in the stack of modules.

Optionally, a module of the module stack comprises a rectifier module between two inverter modules. The rectifier module is configured to distribute current to the two inverter modules via the bus bars. Optionally, the modules of the module stack further comprise a chopper module disposed at an end of the module stack such that one of the two inverter modules is disposed between the rectifier module and the chopper module.

Optionally, the first lifting element has a ramp surface defining at least a portion of an angled contact interface between the first lifting element and the module such that the contact surface of the module slides along the ramp surface to convert lateral movement of the module in the loading direction to vertical movement of the module away from the support platform. Optionally, the first lifting element has an intermediate surface disposed axially between the back wall and the ramp surface, the intermediate surface having a uniform height above the support platform along its length. The intermediate surface of the first lifting element engages the contact surface of the module after the contact surface moves beyond the ramp surface when the module is moved in the loading direction.

Optionally, the first lifting element is mounted on the first guide bar and has a conical shape.

Optionally, the first lifting element is mounted to the rear wall at a location spaced from the first guide bar.

Optionally, the first lifting element is a wedge-shaped member mounted to the support platform.

Optionally, the guide rod is cantilevered and extends from the back wall to a respective distal section of the guide rod. The mounting system also includes a fastener configured to releasably couple to the distal section of the first guide bar to exert a clamping force on the module to secure the module to the frame. Optionally, the first guide bar is threaded and the fastener is a nut configured to be threadably coupled to the distal section of the first guide bar.

Optionally, the first lifting element disposed at or near the back wall is a back lifting element, and the mounting system includes a front lifting element configured to be mounted to the distal section of the first guide bar. The front lifting element has a conical shape that wedges under the module in response to movement of the front lifting element relative to the module in the loading direction to lift the front end of the module off the support platform.

In one or more embodiments, a mounting system is provided that includes a rack and a first module. The frame includes a back wall, a plurality of guide rods connected to and extending from the back wall, a plurality of lift elements disposed at or near the back wall, and a support platform disposed below the guide rods. A first module is configured to be mounted to the chassis in a stack with other modules. The first module has a top side and a bottom side opposite the top side. The first module defines a channel configured to receive a first of the guide bars therein. The channel is spaced above the bottom side by a designated height to enable the first guide bar to enter the channel when the bottom side is disposed on the support platform. The first guide bar is configured to guide movement of the first module relative to the support platform in a loading direction toward the rear wall. When the first module approaches the back wall, a first lifting element of the lifting elements is configured to: the first module is engaged at an angled contact interface between the first lifting element and the first module to lift the first module off the support platform in response to additional movement of the first module in the loading direction. In a fully loaded position relative to the frame, the first module is supported by the rear wall, the first lifting element and/or the first guide bar, and a bottom side of the first module is spaced apart from the support platform by a gap.

Optionally, the mounting system further comprises a second module configured to be mounted to the frame above the first module such that the first module is between the second module and the support platform. The second module is at least partially supported by the top side of the first module when the second module is moved in the loading direction. At least a second lifting element of the lifting elements is configured to engage the second module at an angled contact interface between the second lifting element and the second module to lift the second module off of the first module in response to additional movement of the second module in the loading direction. In the fully loaded position, the second module is supported by the rear wall, the second lifting element, and/or the second guide bar, and the second module is spaced apart from the first module by a gap.

Optionally, the second module defines a channel configured to receive a second guide bar of the guide bar therein to guide movement of the second module in the loading direction. The channel is spaced above the bottom side of the second module by a designated height to enable the second guide bar to enter the channel when the bottom side of the second module is disposed on the top side of the first module.

Optionally, the mounting system further comprises a support member spaced from the rear wall of the rack and mechanically coupled to both the first module and the second module to limit movement of the first module and the second module relative to each other.

Optionally, the first module has a rear side facing the rear wall and a gasket mounted on the rear side. The gasket is configured to be compressed between the back side and the back wall of the first module when the first module is in the fully loaded position.

Optionally, the first module has a front side facing away from the rear wall. The first module includes a shelf projecting from the front side to define a front end of the first module. The stand includes a handle thereon. The top side of the first module extends along the shelf.

Optionally, the channel of the first module comprises a rear opening at a rear side of the first module. The rear opening is countersunk to provide a ramped surface. A ramp surface at the rear opening is configured to engage the first lifting element and define a portion of an angled contact interface that lifts the first module off of the support platform.

Optionally, the first lifting element is mounted to the rear wall at a location spaced from the first guide bar. The first module defines a receptacle at a rear side of the first module. The receptacle is spaced apart from the channel and is configured to receive a first lifting element therein to define a portion of an angled contact interface that lifts the first module off of the support platform.

Optionally, the first lifting element is a wedge-shaped member mounted to the support platform. The first module includes a wedge member mounted on a top side of the first module. The wedge member on the first module represents a second lifting element of the lifting element and is configured to engage a second module mounted to the frame above the first module at an angled contact interface to lift the second module off of the first module in response to additional movement of the second module in the loading direction.

Optionally, the guide rod is cantilevered and extends from the back wall to a respective distal section of the guide rod. The mounting system also includes a fastener configured to releasably couple to the distal section of the guide bar to exert a clamping force on the first module and the other modules for securing the first module and the other modules to the chassis.

In one or more embodiments, a mounting system is provided that includes a module configured to be mounted to a rack. The module includes a housing having a top side, a bottom side opposite the top side, and a rear side extending between the top side and the bottom side. The module defines a channel configured to receive a guide bar of the rack therein. The channel is spaced above the bottom side by a designated height to enable the guide bar to enter the channel when the bottom side is disposed on the support platform. When the bottom side engages the support platform, movement of the module in the loading direction toward the rear wall of the rack is guided by the guide rods within the channel. The module includes a ramp surface extending from the rear side in a transverse orientation relative to the rear side. The ramp surface is configured to engage the lifting element of the rack as the module approaches the rear wall to define an angled contact interface that lifts the module off of the support platform in response to additional movement of the module relative to the lifting element in the loading direction. The bottom side of the module is configured to be spaced apart from the support platform by a gap when the module is in a fully loaded position relative to the frame.

In one or more embodiments, an electrical power delivery system is provided that includes a conductive plane or bus bar, a plurality of electrical energy storage devices, and a support structure. The electrical energy storage device is mounted on and electrically connected to the conductive plane. The electrical energy storage devices extend from a common side of the conductive plane. The support structure is spaced apart from the conductive plane. The support structure engages and at least partially surrounds each of the electrical energy storage devices such that the support structure mechanically supports each of the electrical energy storage devices along at least two support directions that are orthogonal to each other.

Optionally, the at least two support directions are in a common plane parallel to the conductive plane.

Optionally, the conductive plane is oriented parallel to the height axis and the electrical energy storage device projects laterally from a side of the conductive plane parallel to the lateral axis. The support structure supports each electrical energy storage device in a vertical direction parallel to the elevation axis and a longitudinal direction orthogonal to both the elevation axis and the lateral axis.

Optionally, the support structure surrounds at least a majority of a perimeter of each of the electrical energy storage devices.

Optionally, the electrical power delivery system further comprises a frame. The support structure and the conductive plane are separately fixed to the frame. Optionally, the frame is configured to be disposed onboard the vehicle and exposed to vibrations, accelerations, and impact forces during travel of the vehicle. The support structure is configured to: supporting the weight of the electrical energy storage device and reducing forces exerted on the electrical energy storage device due to vibrations, accelerations and impact forces during travel of the vehicle relative to direct attachment of the electrical energy storage device to the frame.

Optionally, the support structure includes a first housing member and a second housing member configured to couple to each other. Each of the first and second housing members defines a set of concave recesses along respective inner sides thereof. When the first housing section is coupled to the second housing section, the inner side faces face each other, and each of the electrical energy storage devices is at least partially surrounded by the corresponding concave recess of the first housing section and the corresponding concave recess of the second housing section.

Optionally, the first housing member includes a rod extending from an inner side thereof. The second housing member defines an aperture configured to receive a rod therein for aligning and guiding coupling of the first and second housing members.

Optionally, the concave recesses of the first and second shell members comprise a compressible liner. The compressible liner is configured to engage and compress between the corresponding housing members and the outer surface of the corresponding electrical energy storage device when the first and second housing members are being coupled together.

Optionally, the first housing section and the second housing section are both configured to move toward each other relative to the electrical energy storage device when the first and second housing sections are being coupled together.

Optionally, the support structure has a unitary, monolithic body defining a plurality of openings therethrough spaced along a surface area of the support structure. Each opening is positioned and sized to receive a different one of the electrical energy storage devices when the support structure is moved relative to the electrical energy storage devices in the mounting direction toward the conductive plane.

Optionally, the support structure has a single, unitary body defining a plurality of recesses along a first side thereof. Each recess is positioned and sized to receive therein a distal end of a different one of the electrical energy storage devices when the support structure is moved relative to the electrical energy storage devices in the mounting direction toward the conductive plane.

Optionally, the support structure comprises a rigid body and a plurality of collars tethered to the rigid body. Each collar engages and wraps around a different one of the electrical energy storage devices.

In one or more embodiments, a support structure for supporting a plurality of electrical energy storage devices cantilevered from a conductive plane is provided. The support structure includes a first housing member and a second housing member. The first shell member has an inner side surface and defines a plurality of concave recesses spaced along the inner side surface. The second shell member has an inner side surface and defines a plurality of concave recesses spaced along the inner side surface. The first and second case members are configured to be coupled to each other around the electrical energy storage device such that the inner sides face each other. When the first and second housing sections are coupled together, the first and second housing sections are spaced apart from the conductive plane, the concave recess of the first housing section engages and surrounds the first perimeter section of the electrical energy storage device, and the concave recess of the second housing section engages and surrounds the second perimeter section of the electrical energy storage device. The second peripheral section is circumferentially spaced from the first peripheral section.

Optionally, the first housing member includes a stem extending from an interior side thereof, and the second housing member defines an aperture that is open along an interior side thereof. The aperture is configured to receive a rod therein for aligning and guiding the coupling of the first and second housing members. Optionally, the rod is threaded and the support structure further comprises a nut threadably coupled to the rod to provide a clamping force to secure the first and second housing sections to the electrical energy storage device.

Optionally, the concave recesses of the first and second shell members comprise a compressible liner. The compressible liner is configured to engage and compress against an outer surface of a corresponding electrical energy storage device when the first and second shell members are coupled together.

Optionally, the first and second housing members are configured to be coupled along a coupling axis. When the first and second housing sections are being coupled together, both the first housing section and the second housing section move relative to the electrical energy storage device along the coupling axis toward each other.

Optionally, the first and second enclosure sections, when coupled to each other around the electrical energy storage device, mechanically support each of the electrical energy storage devices along at least two support directions that are orthogonal to each other in a common plane. The common plane is parallel to the conductive plane from which the electrical energy storage device extends.

In one or more embodiments, an electrical power delivery system is provided that includes a frame, an electrically conductive plane, a plurality of electrical energy storage devices, and a support structure. The frame is configured to be mounted to a vehicle. The conductive plane is fixed to the chassis. The electrical energy storage device is mounted on and electrically connected to the conductive plane. The electrical energy storage devices extend from a common side of the conductive plane. The support structure is spaced apart from the conductive plane and is fixed to the frame. The support structure engages and at least partially surrounds each of the electrical energy storage devices such that the support structure mechanically supports each of the electrical energy storage devices along at least two support directions that are orthogonal to each other. The support structure is configured to: supporting a weight of the electrical energy storage device and reducing a force exerted on the electrical energy storage device due to one or more of vibration, acceleration, or impact forces during travel of the vehicle relative to direct connection of the electrical energy storage device to the frame.

Reference is made to the exemplary embodiments of the present subject matter, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. Certain embodiments of the inventive subject matter are described with respect to off-highway vehicles designed to perform operations associated with a particular industry (e.g., mining, construction, farming, etc.) and may include haul trucks, cranes, earth moving machines, mining machines, farming equipment, tractors, material handling equipment, earth moving equipment, and the like. However, embodiments of the inventive subject matter are also applicable for use with other vehicles, such as road vehicles (e.g., automobiles, tuggers, on-highway dump trucks, etc.), rail vehicles, and marine vehicles. Embodiments of the inventive subject matter are also suitable for use with stationary, non-vehicle applications to deliver electrical power in factories and other industrial environments (settings).

To the extent that the figures illustrate diagrams of the functional blocks of various embodiments, the functional blocks are not necessarily indicative of the division between hardware circuitry. Thus, for example, one or more of the functional blocks (e.g., processors or memories) may be implemented in a single piece of hardware (e.g., a general purpose signal processor, microcontroller, random access memory, hard disk, or the like). Similarly, the programs may be stand alone programs, may be incorporated as subroutines in an operating system, may be functions in an installed software package, and the like. The various embodiments are not limited to the arrangements and instrumentality shown in the drawings.

The description is intended to be illustrative and not restrictive. For example, the embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the inventive subject matter without departing from its scope. While the dimensions and types of materials described herein define the parameters of the inventive subject matter, they are by no means limiting and are exemplary embodiments. Many other embodiments will be apparent to those of ordinary skill in the art upon reading the above description. The scope of the inventive subject matter should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

This written description uses examples to disclose several embodiments of the inventive subject matter, and also to enable any person skilled in the art to practice embodiments of the inventive subject matter, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the inventive subject matter is defined by the claims, and may include other examples that occur to those of ordinary skill in the art. 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.

As used herein, an element or step recited in the singular and proceeded with the word "a" or "an" should be understood as not excluding plural said elements or steps, unless such exclusion is explicitly recited. Furthermore, references to "one embodiment" of the present subject matter are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Furthermore, unless explicitly stated to the contrary, embodiments "comprising," "including," or "having" an element or a plurality of elements having a particular property may include additional such elements not having that property. In the appended claims, the terms "including" and "in which" are used as the plain-english equivalents of the respective terms "comprising" and "wherein. Furthermore, in the following claims, the terms "first," "second," and "third," etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Furthermore, the limitations of the following claims are not written in a means-plus-function format, and are not intended to be interpreted based on the 35 th article 112(f) of the U.S. code, unless and until such claim limitations explicitly use the phrase "means for.

Claims

1. An electrical power delivery system comprising:

a module stack comprising a plurality of modules stacked side-by-side along a stack axis, each of the modules having a respective housing and internal electrical components within the housing;

an electrically conductive bus bar oriented along a plane parallel to the stack axis, the bus bar mounted along a side of the stack of modules and electrically connected to one or more of the modules; and

one or more electrical energy storage devices electrically connected to the bus bar, the one or more electrical energy storage devices extending from a side of the bus bar facing away from the module stack such that the bus bar is disposed between the one or more electrical energy storage devices and the module stack.

2. The electrical power delivery system of claim 1, wherein the internal electrical components of at least two of the modules of the stack of modules have the same configuration, and the internal electrical components of at least one module in the stack of modules are different from the internal electrical components of another module in the stack of modules.

3. The electrical power delivery system of claim 1, wherein the enclosures of the modules of the module stack have the same form factor.

4. The electrical power delivery system of claim 1, wherein the modules of the module stack include a rectifier module between two inverter modules, the rectifier module configured to distribute current to the two inverter modules via the bus bar.

5. The electrical power delivery system of claim 1, wherein the modules of the module stack include at least one inverter module, at least one rectifier module, and at least one chopper module, and a first chopper module of the at least one chopper module is disposed at an end of the module stack.

6. The electrical power delivery system of claim 1, wherein the one or more electrical energy storage devices comprise an array of capacitors mounted to the bus bar, each of the capacitors in the array extending from the bus bar along a respective central axis, wherein the central axes of the capacitors are parallel to each other and perpendicular to both the stack axis and a plane of the bus bar.

7. The electrical power delivery system of claim 1, further comprising a frame, wherein the modules of the stack of modules are mounted to and supported by the frame such that adjacent modules of the stack of modules are spaced apart from each other by a spacing gap.

8. A mounting system for mounting a module on an electrical power delivery system, the mounting system comprising:

a frame comprising a back wall and a support platform;

a plurality of guide rods connected to and extending from the rear wall, the guide rods suspended above the support platform, wherein a first guide rod of the guide rods is spaced a designated height above the support platform such that the first guide rod is receivable within the channel of the module when the module is disposed on the support platform, the first guide rod configured to guide movement of the module relative to the support platform in a loading direction toward the rear wall; and

a plurality of lifting elements disposed at or proximate to the back wall, wherein a first lifting element of the lifting elements is configured to: engaging the module at an angled contact interface between the first lifting element and the module to lift the module off the support platform in response to additional movement of the module in the loading direction,

wherein when the module is in a fully loaded position relative to the frame, the module is supported by one or more of the rear wall, the first lifting element, or the first guide bar, and the module is spaced apart from the support platform by a gap.

9. The mounting system of claim 8, wherein the first lifting element has a ramp surface defining at least a portion of the angled contact interface between the first lifting element and the module such that the contact surface of the module slides along the ramp surface to convert lateral movement of the module in the loading direction to vertical movement of the module away from the support platform.

10. The mounting system of claim 9, wherein the first lifting element has an intermediate surface disposed axially between the back wall and the ramp surface, the intermediate surface having a uniform height along a length of the intermediate surface above the support platform, wherein the intermediate surface of the first lifting element engages the contact surface of the module after the contact surface moves beyond the ramp surface when the module moves in the loading direction.

11. The mounting system of claim 9, wherein the first lifting element is one of: (i) a wedge member mounted on the first guide bar and having a conical shape, (ii) mounted to the back wall at a location spaced apart from the first guide bar, or (iii) mounted to the support platform.

12. The mounting system of claim 8, wherein the guide bar is cantilevered and extends from the back wall to respective distal sections of the guide bar, wherein the mounting system further comprises a fastener configured to be releasably coupled to the distal section of the first guide bar to exert a clamping force on the module to secure the module to the chassis.

13. The mounting system of claim 8, wherein the first lifting element disposed at or proximate to the rear wall is a rear lifting element, and the mounting system includes a front lifting element configured to be mounted to a distal section of the first guide bar, the front lifting element having a conical shape that wedges under the module to lift a front end of the module off the support platform in response to movement of the front lifting element relative to the module in the loading direction.

14. An electrical power delivery system comprising:

a conductive bus bar;

a plurality of electrical energy storage devices mounted to and electrically connected to the electrically conductive bus bars, the electrical energy storage devices protruding from a common side of the electrically conductive bus bars; and

a support structure spaced apart from the electrically conductive bus bar, the support structure engaging and at least partially surrounding each of the electrical energy storage devices such that the support structure mechanically supports each of the electrical energy storage devices along at least two support directions orthogonal to each other.

15. The electrical power delivery system of claim 14, wherein the at least two support directions are in a common plane parallel to the conductive bus bar.

16. The electrical power delivery system of claim 14, wherein the support structure surrounds at least a majority of a perimeter of each of the electrical energy storage devices.

17. The electrical power delivery system of claim 14, further comprising a frame configured to be disposed onboard a vehicle and exposed to vibrations, accelerations, and impact forces during travel of the vehicle, wherein the support structure and the conductive bus bar are separately secured to the frame, and the support structure is configured to: supporting a weight of the electrical energy storage device and reducing forces exerted on the electrical energy storage device due to vibrations, accelerations, and impact forces during travel of the vehicle relative to direct connection of the electrical energy storage device to the frame.

18. The electrical power delivery system of claim 14, wherein the support structure includes first and second enclosure members configured to couple to one another, each of the first and second enclosure members defining a set of concave recesses along respective interior sides thereof, and

wherein the inner side faces face each other when the first housing section is coupled to the second housing section, and each of the electrical energy storage devices is at least partially surrounded by the corresponding concave recess of the first housing section and the corresponding concave recess of the second housing section.

19. The electrical power delivery system of claim 14, wherein the support structure has a unitary, unitary body defining a plurality of openings therethrough spaced along a surface area of the support structure, each of the openings being positioned and sized to receive a different one of the electrical energy storage devices when the support structure is moved relative to the electrical energy storage devices in an installation direction toward the electrically conductive bus bar.

20. The electrical power delivery system of claim 14, wherein the support structure has a single, unitary body defining a plurality of recesses along a first side thereof, each of the recesses being positioned and sized to receive a distal end of a different one of the electrical energy storage devices therein when the support structure is moved relative to the electrical energy storage devices in an installation direction toward the electrically conductive bus bar.