AU2022348890A1

AU2022348890A1 - Electric vehicle power pack module

Info

Publication number: AU2022348890A1
Application number: AU2022348890A
Authority: AU
Inventors: Lawrence AMBROSE; Bevan Dooley
Original assignee: Janus Electric Pty Ltd
Current assignee: Janus Electric Pty Ltd
Priority date: 2021-09-30
Filing date: 2022-09-29
Publication date: 2023-04-27
Anticipated expiration: 2042-09-29
Also published as: WO2023049965A1; AU2023214346A1; AU2022348890B2

Abstract

A power pack (1) comprising a support (2), a drivetrain subassembly (13) and an electric motor (19). The support (2) comprises: a torque tube (3), wherein the torque tube (3) extends between at least a first location (5) and a distal second location (11); a torque mount (7) at the first location (5) of the torque tube (3), wherein the torque mount (7) is configured to mount to a chassis (103) of a prime mover (101); and a torque transfer plate (9) at the second location (11) of the torque tube (3). A housing (15) of the drivetrain subassembly (13) is located inside the torque tube (3) and mounted (16) to the torque transfer plate (9), and wherein an output drive shaft (17) of the drivetrain subassembly (13) passes through the torque mount (7). The electric motor (19) is mounted (20) to the support (2) and is mechanically coupled (21) to drive the drivetrain subassembly (13). Torque (23) at the housing (15) of the drivetrain subassembly (13) is transferred to the chassis (103) via the torque transfer plate (9), the torque tube (3), and the torque mount (7).

Description

"Electric vehicle power pack module"

Technical Field

[0001] The present disclosure relates to a power pack module for a prime mover. In particular, a power pack utilising an electric motor to provide a power output to drive the prime mover.

Background

[0002] Electric vehicles have some advantages over internal combustion engine vehicles, notably reduced (or no) emissions during operation, higher torque and/or power output, and flexibility in energy storage and charging.

[0003] Heavy vehicles, such as prime movers, are large machines that are complex and expensive. Therefore, prime movers often have a large lifespan to amortise costs over time. Furthermore, research and development, as well as tooling, for manufacture of prime movers can involve significant costs. To assist in transition from fleets of internal combustion engine prime movers, it may be desirable to convert existing internal combustion engine prime movers to electric drive or install electric drives into traditionally internal combustion engine powered prime mover models at the original equipment manufacturer factory. This can include conversion by replacing an existing engine and transmission of a diesel prime mover.

[0004] In this description, reference to prime movers include trucks, semi-truck, tractor unit, rig, etc.

[0005] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

[0006] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each claim of this application.

Summary

[0007] The present disclosure includes a power pack that can be mounted to a prime mover. In some examples, the power pack can be a one for one replacements of a diesel power pack. That is, removing a diesel power pack from a prime mover and replacing this with an electric power pack of the present disclosure. In other examples, this includes inserting an electric power pack of the present disclosure into a new glider (i.e. a vehicle without a powertrain) of a prime mover.

[0008] There is disclosed a power pack comprising a support, drivetrain subassembly, and an electric motor. The support comprises: a torque tube, wherein the torque tube extends between at least a first location and a distal second location; a torque mount at the first location of the torque tube, wherein the torque mount is configured to mount to a chassis of a prime mover; and a torque transfer plate at the second location of the torque tube. A housing of the drivetrain subassembly is located inside the torque tube and mounted to the torque transfer plate, and wherein an output drive shaft of the drivetrain subassembly passes through the torque mount. The electric motor is mounted to the support, wherein the electric motor is mechanically coupled to drive the drivetrain subassembly. Torque at the housing of the drivetrain subassembly is transferred to the chassis via the torque transfer plate, the torque tube, and the torque mount.

[0009] In some examples of the power pack, the drivetrain subassembly comprises a transmission which may contain sufficient multiple gears ratios to allow for high prop shaft torque (low gear) or overdrive capability or any ratio between.

[0010] In some examples of the power pack, the support further comprises: an extension distal to the first location and the second location, wherein the electric motor is mounted to the extension, and wherein torque at a motor housing is transferred to the chassis via the extension, torque tube, and the torque mount. [0011] In some examples of the power pack, the extension is a half-pipe extending from the torque tube.

[0012] In some examples, the power pack comprises one or more of:

- a power inverter to convert direct current from the electric power source to alternating current or DC pole switching for the electric motor;

- a power steering system;

- a water cooling system;

- an air compressor system;

- an air conditioning system

- power inverter(s) to convert direct current from the electric power source to drive the above systems; and

- a direct current voltage converter to supply low voltage accessory power.

[0013] In some examples of the power pack, the torque mount is configured to replicate a mounting interface of a diesel engine power pack. In some examples, the torque mount is in a form of a torque ring. The torque ring may be substantially circular, square, hexagonal, or other annular shape.

[0014] In some examples, the power pack is a module configured to replace a power pack of a diesel prime mover.

[0015] In some examples, the power pack further comprises: a shaft extension coupled to the output drive shaft, and extending to a third location opposite to the first and second locations of the torque tube; and a shaft support extending from the torque mount, wherein the shaft support includes a bearing to support the shaft extension at the third location. [0016] There is also disclosed a prime mover comprising a chassis and a power pack described above.

[0017] There is also disclosed a support to mount an electric motor and drivetrain subassembly to a chassis of a prime mover, the support comprising: a torque tube, wherein the torque tube extends between at least a first location and a distal second location, and configured to receive the drivetrain subassembly inside the torque tube; a torque mount at the first location of the torque tube, wherein the torque mount is configured to mount to the chassis of the prime mover; and a torque transfer plate at the second location of the torque tube, and configured to mount the drivetrain subassembly, wherein the support is configured to mount the electric motor, and wherein torque at a housing of the drivetrain assembly is transferred to the chassis via the torque transfer plate, the torque tube, and the torque mount.

[0018] In some examples, the support further comprises: an extension distal to the first location and the second location, wherein the electric motor is mounted to the extension, and wherein torque at a motor housing is transferred to the chassis via the extension, torque tube, and the torque mount.

[0019] In some examples of the support, the extension is a half-pipe extending from the torque tube.

[0020] In some examples the support is further configured to mount one or more of:

- a power steering system;

- a water cooling system;

- an air compressor system;

- an air conditioning system;

- a direct current voltage converter to supply low voltage accessory power; and

- inverter(s) to power all of the above. [0021] In some examples of the support, the torque mount is configured to replicate a mounting interface of a diesel engine power pack. In some examples, the torque mount is in the form of a torque ring.

[0022] In some examples the support further comprises: a shaft extension coupled to the output drive shaft, and extending to a third location opposite to the first and second locations of the torque tube; and a shaft support extending from the torque mount, wherein the shaft support includes a bearing to support the shaft extension at the third location.

Brief Description of Drawings

[0023] Examples of the disclosure are described with reference to the following Figures:

[0024] Fig. 1 is a perspective cut-away view of a power pack for a prime mover;

[0025] Fig. 2 is an alternative perspective view of the power pack of Fig. 1 ;

[0026] Fig. 3 is view of part of the power pack of Fig. 1 showing a first torque tube component supporting a drivetrain subassembly and electric motor;

[0027] Fig. 4 is a view of part of the power pack of Fig. 1 showing a second torque tube component supporting a frame that in turn supports other components of the power pack;

[0028] Fig. 5 illustrated a partial cross-section of a prime mover with the power pack of Fig. 1;

[0029] Fig. 6 illustrates the power pack in an engine bay of a prime mover;

[0030] Fig. 7 is a front view of a power pack in an engine bay of a prime mover;

[0031] Fig. 8 is a variation of the power pack 1 with a shaft extension and shaft support;

[0032] Fig. 9 illustrate a perspective cut-of a variation of a power pack for a prime mover with the electric motor housing mounted directly to the torque transfer plate; [0033] Fig. 10 illustrates an alternative perspective view of the power pack of Fig. 9;

[0034] Fig. 11 illustrates a cut-away view of the power pack of Fig. 9; and

[0035] Fig. 12 illustrates a cut-away view of the power pack of Fig. 10.

Description of Embodiments

[0036] Overview

[0037] An example of an electric power pack 1 for use with a prime mover 101 is illustrated in Figs. 1 to 7. The power pack 1 includes an electric motor 19 and a drivetrain subassembly that are mounted to a support 2. The support 2, in turn, is mounted to a chassis 103 of a prime mover 101.

[0038] The support 2 includes a torque tube 3 extending between a first location 5 and a distal second location 11. A torque mount 7 is mounted at the first location 5 of the torque tube 3, wherein the torque mount 7 is configured to mount to a chassis 103 of the prime mover 101. In some examples, this is the same mounting point on the chassis 103 as would a diesel engine power pack be mounted to the chassis 103. Thus the torque mount 7 may emulate the mounting interface to the chassis 103.

[0039] The support 2 also includes a torque transfer plate 9 mounted at the second location 11 of the torque tube 3. A housing 15 of the drivetrain subassembly 13 (e .g . a transmission) is located inside the torque tube 3 and mounted 16 to the torque transfer plate 9. An output drive shaft 17 of the drive train subassembly 13 passes through the torque mount 7, so that the output drive shaft 17 can be coupled to other drivetrain components, such as a prop shaft.

[0040] The electric motor 19 is mounted to the support 2, and the electric motor 19 is mechanically coupled 21 to drive the drivetrain subassembly 13.

[0041] The power pack 1 is configured so that in use, torque 23 at the housing 15 of the drivetrain subassembly is transferred to the chassis 103 via the torque transfer plate 9, the torque tube 3, and the torque mount 7. In some examples, at least part of the torque at a motor housing 27 is also transferred to the chassis 103 via the support 2. The support 2 advantageously transfers torque to appropriate mounting locations in the chassis 103 that may correspond, at least in part, to mounting locations for an engine block.

[0042] Components of a non-limiting example of the power pack 1 and prime mover 101 will now be described in detail.

[0043] Support 2

[0044] The support 2 functions to transfer torque from components including those from the housing of the drivetrain subassembly 13 and the electric motor 19 to the chassis via the torque tube 3. The support 2 may also function as a base to which other components of the power pack 1 are mounted.

[0045] The torque tube 3 includes a substantially hollow cylindrical body section. In other examples the torque tube may include other hollow tube formations. For example, the torque tube may have a substantially rectangular, square, pentagonal, hexagonal shaped cross sections. In some examples, the comers of these shapes may be rounded to reduce stress.

[0046] The hollow body section transfers torque from the first location 5 to the second location 11. The torque tube 3 may be constructed in multiple pieces, such as two hollow semi-circular cylinders halves that are joined to complete a full hollow cylinder. As illustrated in Fig. 2, the torque tube 3 is constructed with two pieces, including a first torque tube component 31 and a second torque tube component 33 that are joined together at flanges 35. In this example, the first torque tube component 31 is substantially a complete tube near the first location 5 to provide a robust structure to mount the torque mount 7. Distal to the first location 5, the upper portion of the first torque tube component 31 is open to provide easy access to the inside of the torque tube 3, which may include access to the drivetrain subassembly 13 within as best illustrated in Fig. 3. This can be useful for assembly or maintenance of the power pack 1. This open portion of the first torque tube component 31 is closed by mating the second torque tube component 33 at the flanges 35. The flanges 35 may include apertures to assist fastening the first and second torque tube components 31, 33 together. [0047] As illustrated in Fig. 1, the drivetrain subassembly 13, which in this example includes the transmission, is housed inside the torque tube 3. This provides a compact form to achieve torque transfer from the torque transfer plate 9 to the torque mount 7.

[0048] The torque tube 3 can include an extension 25 to support the electric motor 19. As shown in Fig. 1, the extension 25 extends distal to both the first and second location 5, 11, and extends from the lower first torque tube component 31. The extension 25 in this example is a half-pipe and may be manufactured with, and integral to, the first torque tube component 31 for strength. In the illustrated example, the extension 25 supports the electric motor 19 from below, and torque at the motor housing 27 is transferred to the chassis 103 via the extension 5, torque tube 3, and the torque mount 7. The area above the electric motor 19 is open to assist with cooling of the electric motor 19.

[0049] The torque tube 3 may be manufactured of metal and metal alloys. In some examples, this includes manufacturing components of the torque tube 3 as an extrusion. In some examples, the components of the torque tube 3 are manufactured as forged components. In yet other examples, components of the torque tube 3 are manufactured by casting. In yet further examples, components of the torque tube 3 are manufactured by machining. It is to be appreciated that a combination of the above techniques can be used.

[0050] In some examples, one or more components of the torque tube 3 comprise composite materials. This can include fibre-reinforced plastics that are reinforced with carbon fibre, glass fibre, aramid fibre, etc. as carbon fibre, fibre.

[0051] At the first location 5 of the torque tube 3 is a torque mount 7. The torque mount 7 includes a substantially annular portion to allow an output drive shaft (or coupling for a drive shaft) of the drivetrain subassembly 13 to pass through. In some examples, the torque mount 7 is in the form of a substantially circular ring, square, rectangle, pentagon, hexagon, or other annular form. The torque mount 7 is configured to replicate a mounting interface of a power pack, such as a diesel power pack. This can include a flat mounting surface with a plurality of apertures to enable fasteners to fasten the torque mount 7 to the chassis (103), or other load bearing component, of the prime mover 101. [0052] In some examples, the torque mount 7 is welded to the first torque tube component 31 (or other component(s) forming the torque tube). In other examples, the torque mount 7 is manufactured to be integrally formed with the first torque tube component 31. In yet other examples, the torque mount 7 is fastened to the torque tube 3 with fasteners.

[0053] Referring to Fig. 1, the torque transfer plate 9 at the second location of the torque tube 3 functions to transfer torque from the housing 15 of the drivetrain subassembly 13 to the torque tube 3 which in turn transfers the torque to the torque mount 7 and then to the chassis 103. In this example, the torque transfer plate is located inside the torque tube 3, so that both the torque transfer plate and the housing of the drivetrain subassembly 13 are located inside the torque tube 3.

[0054] The torque transfer plate 9 can be attached to the torque tube 3 by welding. In one example, this includes welding to the first torque tube component 31. In further examples, the torque transfer plate 9 is also welded, or otherwise mounted, to the second torque tube component 33. In yet further examples, the torque transfer plate 9 is mounted to the torque tube 3 with fasteners.

[0055] The torque transfer plate 9 has a central aperture 21 to allow a mechanical coupling (such as a shaft) to transfer rotatory movement from the electric motor 19 (on one side of the torque transfer plate 9) to drive the drivetrain subassembly 13 (on the opposite side of the torque transfer plate 9).

[0056] Drivetrain subassembly 13

[0057] The drivetrain subassembly 13 functions to mechanically transfer power and torque from the electric motor 19 to drivetrain components. This can include an output drive shaft 17 of the drivetrain subassembly 13 that is connected to a prop shaft to drive one or more wheels of the prime mover. In one example the drivetrain subassembly 13 includes a transmission (e.g. gearbox) to provide a one or more gear ratios to change the speed and torque between an input and output. In some examples, the transmission can be a multi-ratio transmission to enable selection of different ratios between the input and output. [0058] In some examples, the drivetrain subassembly 13 may include a gearbox from a diesel power pack system or the existing gearbox of a converted diesel prime mover. In other examples, the drivetrain subassembly is a modified gearbox with gear ratios optimised for the power and torque output of the electric motor 19.

[0059] In some examples, especially those derived from diesel systems, the drivetrain subassembly 13 includes a manual gearbox including a clutch system to selectively couple power from the electric motor 19. In other examples, the drivetrain subassembly 13 may include an automatic transmission with a torque converter. It is to be appreciated that other variations are possible, including robotically operated clutch and gear shifting systems.

[0060] To provide changes to input and output ratios, the transmissions may include gears, belts, chains, or other technologies such as continuously variable transmissions.

[0061] In some alternative examples, the drivetrain subassembly 14 has a single fixed ratio between input from the electric motor 19 and the output drive shaft 17. In yet other alternative examples, the drivetrain subassembly 14 has an input and output that is in direct one to one ratio, such a single drive shaft.

[0062] The drivetrain subassembly 13 also includes a housing 15 to house at least part of the components therein such as the gears, transmission shafts, fluids, lubricants, etc. When the electric motor drives components of the drivetrain subassembly 13 some resultant reaction torque is transmitted to the housing 15. To counteract this torque, the housing 15 is constructed of substantially rigid materials (such as metal or metal alloys). The housing 15, in turn, is mounted to the torque transfer plate 9 to transfer this torque to the support 2.

[0063] In some examples, the housing 15 is mounted to the torque transfer plate 9 in a similar manner to how a gearbox of a diesel power pack is mounted to a diesel engine. This can include mounting with fasteners, such as bolts, that are received in the housing 15 and torque transfer plate 9.

[0064] Electric motor 19

[0065] The electric motor 19 drives a rotor that is coupled to the drivetrain subassembly 13. In some examples, the electric motor includes one of: • Alternating current motor - This can include synchronous or alternatively asynchronous motors.

• Direct current motor. In some examples, this can include a 750 volt DC 6 or 9 phase permanent magnet DC motor.

[0066] The rotor in this example, provides rotation to an output that is in a longitudinal configuration. This replicates the configuration of typical internal combustion engines used with prime movers to simplify adaptation and retrofit of the electric power pack 1.

[0067] The stator of the electric motor 19 is fixed relative to a housing of the electric motor 19. The housing of the electric motor 19 is mounted to the support 2 to: (i) support the mass of the electric motor 19; and (ii) to resist torque when the electric motor 19 is operational. In the illustrated example, this includes mounts 20 to fix the housing of the electric motor 19 to the extension 25. The mounts 20 in this example are fixed to radially extending flanges 37 of the extension 25.

[0068] Other components of the power pack 1

[0069] The power pack 1 may also include other features to support operation of the prime mover 1. This can include motor controller(s) for the electric motor 19. For examples with an AC electric motor 19, this can include a power inverter 41 to convert direct current from the electric power source to alternating current for the electric motor 19. The inverter 41 may include a bank of inverters to provide redundancy and cooling. An inverter support 43 is attached to, and extends from, the support 2 and functions to hold the inverter(s) 41 in place and may also provide shielding and protection.

[0070] It is to be appreciate that other electric power and motor controllers can be used based on the type of power source and electric motor combination. For example, changing the DC voltage for DC electric motors or pole switching on permanent magnet motors.

[0071] The power pack 1 may also include direct current voltage converters (not shown) to supply low voltage accessory power for other systems in the prime mover, such as cabin electrics. [0072] The power pack 1 module may also include part of a power steering system (43), such as a power steering pump to provide hydraulic pressure for power steering. This may also include part of a water cooling system (45) such as a water pump to circulate cooling water (where the radiator may be located separate to the power pack 1 or as part of the power pack 1). The power pack 1 may also include part of an air compressor system 47, such as a pneumatic pump and accumulator, to provide compressed air for the prime mover and trailers. The compressed air may be used for air brakes and air bag suspensions for the prime mover and trailer(s). The power pack 1 may also include part of an air conditioning system 49 to provide air conditioning for the cabin. - The power pack 1 may also include power inverter(s) to convert direct current from the electric power source to drive the above systems

[0073] The various components described above may be supported by a frame 51 attached to the support 2. This is illustrated in Fig. 4, where the frame 51 is supported by the second torque tube component 33. In some example, the second torque tube component 33, frame 51 and other examples can be considered a sub module of the power pack 1.

[0074] The inclusion of the above mentioned components may mirror those components that are included with some diesel power pack systems. This enables the power pack 1 to be a module that easily replaces a power pack of a diesel prime mover 101. Thus when retrofitting the power pack 1 to convert a diesel prime mover 101, or fitting into a prime mover glider, a mechanic may connect similar fitting (e.g. hoses, pipes, connectors) to corresponding compatible components on the prime mover. In some examples, this assist the power pack 1 to be part of a kit to replace a diesel engine.

[0075] Prime mover 101 and chassis 103

[0076] An example of a prime mover 101 having the power pack 1 is illustrated in Figs. 5 to 7. The prime mover 101 includes a chassis 103 that includes a ladder frame extending substantially from the front to rear of the prime mover 103. The chassis 103 supports components including the suspension system, the driver cabin 109.

[0077] The power pack 1 is mounted to the chassis 103 underneath the bonnet at the front of the prime mover 103. The power pack 1 may be sized and configured as a one for one replacement for a diesel engine of the prime mover 101. [0078] The power pack may also be mounted under the cabin in the case of a cab-over truck configuration

[0079] At the side of the chassis 103 are battery packs 105. The battery packs 105 may be mounted to either side of the chassis 103. The battery pack 105 may be sized and configured to replace fuel tanks at the side of the chassis 103 of a diesel prime mover. The battery packs 105 may include a single battery pack module for each side that comprise of a plurality of battery cells. A single battery pack module may facilitate fast change of the battery cell module for servicing, charging, and/or replacement. This reduces down time during battery pack module replacement.

[0080] In other examples, the battery pack 105 include a plurality of individually replaceable modules. This may allow quick change of specific battery modules that need servicing, charging, or replacement.

[0081] The battery pack 105 may also incorporate stairs built onto the side for driver access to the cabin as is common with side mount diesel fuel tanks

[0082] In some examples, the prime mover 1 is converted a diesel prime mover vehicle. The diesel power pack and fuel tanks are removed from the donor vehicle and replaced by the electric power pack 1 and battery packs 105. Advantageously, the power pack 1 includes many interfaces that are similar to those of the diesel power pack to facilitate the swap. This may include how the power pack 1 is mounted to the chassis 103 and coupling of the transmission to the prop shaft. This may also include connections to other components such as compressed air, power steering fluid, cooling water, air-conditioning, and accessory power. The conversion may include replacing diesel fuel lines with electrical cabling to transfer power between the battery packs 105 to the power pack 1.

[0083] In yet other examples, the power pack 1 is mated to a new glider of a prime mover 1. That is, the prime mover 1 that was built without a power pack 1. This may be useful in instances where a prime mover manufacturer provides the chassis and other components but leaves the customer to selectively choose a power pack option.

[0084] Advantages [0085] In existing diesel prime movers, the engine block can function as a rigid support to transfer torque to the chassis of the prime mover. In some examples, other components, such as the transmission, are mounted to the engine block, and torque at a housing of the transmission is transferred to the engine block which in turn transfers torque to the chassis at particular mounting points. In an electric vehicle, components have distinctly different form factors. For example, an electric motor is typically much smaller than an equivalent power diesel engine and typically do not have a motor housing that is as rigid as an engine block or designed to accommodate the torque from high reduction gearboxes. However, converting a prime mover to use an electric motor is not a simple matter of fastening the electric motor or transmission to the closest rigid structure in the engine bay. The substantial torque (and other associated forces) may result in bending of the chassis, or other components of the prime mover 101.

[0086] An advantage of the disclosed power pack 1 is the support (including the torque tube) that transfers torque to mounting points in the chassis. In particular, transferring torque (and other forces) to the mounting points in the chassis that would be experienced if the prime mover had used a diesel power pack / gearbox. The advantage is that the truck chassis does not need substantial redesign or modification to use the disclosed electric power pack. This can facilitate one for one replacement of a diesel power pack with an electric power pack.

[0087] Examples of the power pack 1 also include other components that are attached to, or associated with, a diesel power pack. For example, components such as air compressors, cooling systems, air conditioning, etc. This further facilitates conversion to enable the electric power pack to be easily integrated with existing prime movers without substantial modification.

[0088] Variations

[0089] In the illustrated example, the extension 25 is a half-pipe. However, in one variation the extension 25 may be a circular pipe that is part of (or extension of) the torque tube 3. That is, the cylindrical torque tube 3 structure envelops both the electric motor 19 and the drivetrain subassembly (with the torque transfer plate 9 in between). [0090] Shaft extension 65 and shaft support 63

[0091] A variation of the power pack 1 with a shaft extension 65 and shaft support 63 is illustrated in Fig. 8. The shaft extension 65 extends to a third location 64 to provide a mechanical coupling from the output drive shaft 17 of the drivetrain subassembly 13 to a prop shaft (not show) of the prime mover. The third location 64 is on the opposite side of the torque mount 7 compared to the torque tube 2. The power pack 1 with an electric motor 19 may be significantly shorter than the replaced diesel power pack. In some examples, the electric motor may be around 1 meter shorter than the equivalent diesel engine. Therefore, to use existing attachments points in the chassis 103, the shaft extension 65 is used to extend the output drive shaft 17 to the original location of the prop shaft (or other component, such as a universal joint, etc.).

[0092] The illustrated example includes a shaft support 63 that is mounted to, and extends from, the torque mount 7. The shaft support 63 acts as a hanger mount to support the shaft extension 65 via a bearing 67. The shaft extension 65 also include a shaft extension output 69 to mate with the prop shaft (not shown).

[0093] Fig. 8 also illustrates a bracket 61 that interfaces with the torque mount 7. This bracket 61 can be mounted to the ladder frame of the prime mover. In some examples. The bracket 61 is part of the chassis 103.

[0094] Electric motor mounted to the torque transfer plate 9

[0095] In some variations, the electric motor housing is mounted directly to the torque transfer plate 9 as illustrated in Figs. 9 to 12. This may enable the housing 27 of the electric motor 19 and the housing 15 of the drivetrain subassembly 13 to impart torque on the common transfer plate 9 that, in turn, transfers torque to the chassis 103 via the torque tube 3.

[0096] Referring to Figs. 10 and 12, the housing 27 of the electric motor 19 is mounted 22 to the torque transfer plate 9 with a plurality of bolts. In some examples, directly mounting the electric motor 19 to the torque transfer plate 9 may facilitate alignment of drive components. Thus this illustrated example enables the electric motor 19 to be mounted without further mounts 20 that connects the motor 19 to the extension 25 (as provided in earlier examples illustrated in Figs. 1 and 2).

[0097] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

Claims

CLAIMS:

1. A power pack (1) comprising:

- a support (2) comprising:

- a torque tube (3), wherein the torque tube (3) extends between at least a first location (5) and a distal second location (11);

- a torque mount (7) at the first location (5) of the torque tube (3), wherein the torque mount (7) is configured to mount to a chassis (103) of a prime mover (101); and

- a torque transfer plate (9) at the second location (11) of the torque tube (3);

- a drivetrain subassembly (13), wherein a housing (15) of the drivetrain subassembly (13) is located inside the torque tube (3) and mounted (16) to the torque transfer plate (9), and wherein an output drive shaft (17) of the drivetrain subassembly (13) passes through the torque mount (7); and

- an electric motor (19) mounted (20) to the support (2), wherein the electric motor (19) is mechanically coupled (21) to drive the drivetrain subassembly (13), wherein torque (23) at the housing (15) of the drivetrain subassembly (13) is transferred to the chassis (103) via the torque transfer plate (9), the torque tube (3), and the torque mount (7).

2. A power pack (1) according to claim 1 wherein the drivetrain subassembly (13) comprises a transmission.

3. A power pack (1) according to any one of the preceding claims wherein the support (2) further comprises:

- an extension (25) distal to the first location (5) and the second location (11), wherein the electric motor (19) is mounted (20) to the extension (25), and wherein torque at a motor housing (27) is transferred to the chassis (103) via the extension (25), torque tube (3), and the torque mount (7).

4. A power pack (1) according to claim 3, wherein the extension (25) is a half-pipe extending from the torque tube (3).

5. A power pack (1) according to either claim 1 or 2, wherein the electric motor (19) is mounted to the torque transfer plate (9), wherein torque at a motor housing (27) is transferred to the chassis (103) via the torque transfer plate (9), the torque tube (3), and the torque mount (7).

6. A power pack (1) according to any one of the preceding claims, further comprising one or more of:

- a power inverter (41) to convert direct current from the electric power source to alternating current or DC pole switching for the electric motor (19);

- a power steering system (43);

- a water cooling system (45);

- an air compressor system (47);

- an air conditioning system (49);

- a direct current voltage converter to supply low voltage accessory power.

7. A power pack (1) according to any one of the preceding claims, wherein the torque mount (7) is configured to replicate a mounting interface of a diesel engine power pack.

8. A power pack (1) according to any one of the preceding claims, wherein the power pack (1) is a module configured to replace a power pack (1) of a diesel prime mover (101). 19

9. A power pack (1) according to any one of the preceding claims, further comprising:

- a shaft extension (65) coupled to the output drive shaft (17), and extending to a third location (64) opposite to the first and second locations (5, 11) of the torque tube (2); and

- a shaft support (63) extending from the torque mount (7), wherein the shaft support includes a bearing (67) to support the shaft extension (65) at the third location (64).

10. A prime mover (101) comprising a chassis (103) and a power pack (1) according to any one of claims 1 to 9.

11. A support (2) to mount an electric motor (19) and drivetrain subassembly (13) to a chassis (103) of a prime mover (101), the support (2) comprising:

- a torque tube (3), wherein the torque tube (3) extends between at least a first location (5) and a distal second location (11), and configured to receive the drivetrain subassembly (13) inside the torque tube (3);

- a torque mount (7) at the first location (5) of the torque tube (3), wherein the torque mount (7) is configured to mount to the chassis (103) of the prime mover (101); and

- a torque transfer plate (9) at the second location (11) of the torque tube (3), and configured to mount the drivetrain subassembly (13), wherein the support (2) is configured to mount the electric motor (19), and wherein torque (23) at a housing (15) of the drivetrain assembly (13) is transferred to the chassis (103) via the torque transfer plate (9), the torque tube (3), and the torque mount (7).

12. A support (2) according to claim 11 further comprising:

- an extension (25) distal to the first location (5) and the second location (11), wherein the electric motor (19) is mounted (20) to the extension (25), and 20 wherein torque at a motor housing (27) is transferred to the chassis (103) via the extension (25), torque tube (3), and the torque mount (7).

13. A support (2) according to claim 12, wherein the extension (25) is a half-pipe extending from the torque tube (3).

14. A support (2) according to claim 11 configured to mount the electric motor (19) to the torque transfer plate (9), wherein torque at a motor housing (27) is transferred to the chassis (103) via the torque transfer plate (9), the torque tube (3), and the torque mount (7).

15. A support (2) according to any one of claims 11 to 14, wherein the support (2) is further configured to mount one or more of:

- a power steering system;

- a water cooling system;

- an air compressor system;

- an air conditioning system;

- a direct current voltage converter to supply low voltage accessory power.

16. A support (2) according to any one of claims 11 to 15, wherein the torque mount (7) is configured to replicate a mounting interface of a diesel engine power pack.

17. A support (2) according to any one of claims 11 to 16, further comprising:

- a shaft extension (65) coupled to the output drive shaft (17), and extending to a third location (64) opposite to the first and second locations (5, 11) of the torque tube (2); and - a shaft support (63) extending from the torque mount (7), wherein the shaft support includes a bearing (67) to support the shaft extension (65) at the third location (64).