The embodiments described herein are generally directed to swapping battery packs, and, more particularly, to mobile equipment optimized for swapping battery packs at industrial sites.
In some industrial contexts, such as construction, mining, farming, forestry, and the like, battery-powered mobile equipment may operate in remote locations, such as off-road locations, where no supporting infrastructure exists. Access to these sites can potentially be a complex task due to several factors specific to these environments. Mobile equipment often operate in demanding and dynamic conditions, requiring continuous usage throughout the day. The process of recharging the batteries of such mobile equipment can be time-consuming. Therefore, it becomes costly for businesses to operate an efficient recharging process.
Traditionally, industrial sites may have limited infrastructure for charging mobile equipment. The availability and placement of charging stations need to be carefully planned to ensure convenient access and avoid congestion. Furthermore, the power supply capacity at these locations might be limited, requiring careful management of energy resources to prevent overloading the electrical infrastructure or causing power disruptions.
In addition, the mobility of the equipment itself poses logistical challenges. Mobile equipment may need to be relocated to charging stations, which requires efficient coordination and management of operations to avoid disruptions or delays in workflow. The diversity of mobile equipment used in industrial sites further complicates the recharging process.
The present disclosure is directed toward overcoming one or more of the problems discovered by the inventors.
In an embodiment, a battery-swapping assembly comprises a frame configured to support a battery pack, wherein the frame includes a body, two arms extending from the body, wherein each of the two arms includes a first end, joined to the body, and a second end, and a removable stiffener between the second ends of the two arms.
In an embodiment, a battery-swapping assembly comprises a frame configured to support a battery pack, wherein the frame includes a body, two arms extending from the body, wherein each of the two arms comprises a first end, joined to the body, and a second end, a removable stiffener between the second ends of the two arms, a movement system, wherein the movement system includes two or more movement elements, wherein each of the two or more movement elements includes a cylinder barrel, a piston rod that is configured to extend outward from the cylinder barrel and contract inward into the cylinder barrel, and an attachment point at an end of the piston rod, and wherein each attachment point is configured to attach to the battery pack; a first traction motor coupled to a first one of the two arms; a first ground-engaging member that is driven by the first traction motor; a second traction motor coupled to a second one of the two arms; and a second ground-engaging member that is driven by the second traction motor.
In an embodiment, a battery-swapping system comprises a mobile equipment that includes a frame configured to support a battery pack, wherein the frame includes a body, two arms extending from the body, wherein each of the two arms comprises a first end, joined to the body, and a second end, and a removable stiffener extending across an area between the second ends of the two arms; and a mobile battery-swapping system comprising a platform configured to move one or both of vertically or horizontally, wherein the platform is configured to engage and carry the battery pack through the area between the seconds ends of the two arms while the removable stiffener is removed.
The details of embodiments of the present disclosure, both as to their structure and operation, may be gleaned in part by study of the accompanying drawings, in which like reference numerals refer to like parts, and in which:
The detailed description set forth below, in connection with the accompanying drawings, is intended as a description of various embodiments, and is not intended to represent the only embodiments in which the disclosure may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of the embodiments. However, it will be apparent to those skilled in the art that embodiments of the invention can be practiced without these specific details.
In some instances, well-known structures and components are shown in simplified form for brevity of description. For clarity and ease of explanation, some surfaces and details may be omitted in the present description and figures. It should also be understood that the various components illustrated herein are not necessarily drawn to scale. In other words, the features disclosed in various embodiments may be implemented using different relative dimensions within and between components than those illustrated in the drawings.
In the illustrated example, mobile equipment 100 includes a rear portion 110 and a front portion 120 that includes a worktool 125. Front portion 120 may be articulated with respect to rear portion 110, by virtue of a joint 112, such that front portion 120 is capable of rotating within a range of degrees, relative to rear portion 110, around an axis A. However, it should be understood that disclosed embodiments do not require mobile equipment 100 to comprise an articulated front portion 120. In an alternative example, mobile equipment 100 may comprise non-articulated front and rear portions (e.g., a single, integrated body frame).
Mobile equipment 100 may comprise at least one, and generally a plurality of, ground-engaging members 130. Ground-engaging members 130 are illustrated as wheels. In an alternative embodiment, ground-engaging members 130 may comprise a track or pair of tracks. More generally, ground-engaging member(s) 130 may comprise any mechanism for supporting mobile equipment 100 above the ground, and preferably moving mobile equipment 100 relative to the ground.
Rear portion 110 of mobile equipment 100 comprises a rear bumper 114 on the rear end. Rear portion 110 also comprises a rear frame 140, which supports a battery pack 150. Rear frame 140 may be shaped in u-shape or an angled-ended. U-shaped frame 140 may allow battery pack 150 to be disconnected and lowered directly to the ground beneath the mobile equipment 150, allowing mobile equipment to pull forward, and then reverse to the next battery pack 150 and install it. Angle-ended frame 140 may allow a battery pack 150 to be lowered/slid off of mobile equipment 100 and to the ground, and mobile equipment to then drive and pick up the next battery pack 150. Battery pack 150 powers mobile equipment 100, including powering the motor(s) that drive ground-engaging member(s) 130, worktool 125, electronic control units (ECUs), electronics within the cabin, and/or the like.
As used herein, a reference numeral without an appended letter, but with the same numerical component as a reference numeral with an appended letter, will be used to refer to that component generically. For example, the term “arm 142” may refer to either arm 142A or arm 142B, and the term “arms 142” may refer collectively to arms 142A and 142B.
In an embodiment, frame 140 also comprises a stiffener 146. Stiffener 146 may be positioned at the rear of battery pack 150, between the rear ends of arms 142A and 142B. When inserted between the rear ends of arms 142A and 142B, stiffener 146 supports arms 142A and 142B outwards. In particular, stiffener 146 supports arms 142 against buckling or other forces that may cause arms 142 to twist or otherwise collapse inwards.
In an embodiment, stiffener 146 may also extend vertically past the bottom of battery pack 150. Thus, stiffener 146 may prevent battery pack 150 from moving (e.g., translating) towards the rear of mobile equipment 100, in addition to providing support to arms 142. In addition, stiffener 146 may cover the rear of mobile equipment 100 to prevent exposure of battery pack 150 to the external environment of mobile equipment 100.
Stiffener 146 may be removable. For example, stiffener 146 may be configured to slide out through the rear end of mobile equipment 100, between portions 114A and 114B of rear bumper 114. In this case, stiffener 146 may completely detach from frame 140. Alternatively, stiffener 146 may rotate horizontally outwards or vertically up or down, without completely detaching from frame 140. In this case, stiffener 146 may be joined to frame 140 via a hinge or other joint mechanism. In either case, whether completely detachable or not, stiffener 146 may be removable from within the space between arms 142A and 142B, to thereby provide access to the compartment, in rear portion 110 of mobile equipment 100, in which battery pack 150 is mounted. When between arms 142A and 142B, stiffener 146 may be fastened to frame 140, in any known manner, to thereby prevent removal. For example, stiffener 146 may be fastened to frame 140 via bolts, screws, clips, latches, and/or the like.
In an embodiment, the size of battery pack 150 prevents an axle from being placed between ground-engaging members 130A and 130B on rear portion 110. In this case, each ground-engaging member 130 on rear portion 110 may be powered by a discrete traction motor 135. For example, ground-engaging member 130A may be powered by traction motor 135A, and ground-engaging member 130B may be powered by traction motor 135B. Each traction motor 135 may utilize motor reduction and an active suspension.
As illustrated in
Each vertical movement element 350 may be operated in synchrony with each other vertical movement element 350. As each piston rod 354 extends out of cylinder barrel 352, battery pack 150 is gradually dropped vertically downward and out of rear portion 110 by virtue of the couplings between battery pack 150 and attachment points 356, as illustrated in
Conversely, a new or recharged battery pack 150 may be positioned on the ground G underneath rear portion 110 (e.g., by moving mobile equipment 100 rearward over battery pack 150 and/or moving battery pack 150 under mobile equipment 100 from the rear end) and coupled to attachment points 356. Then, as each piston rod 354 contracts into cylinder barrel 352, battery pack 150 is gradually lifted vertically upward into rear portion 110 by virtue of the couplings between battery pack 150 and attachment points 356. Once lifted, battery pack 150 may be fixed into position within rear portion 110 via any coupling mechanism (e.g., bolts, screws, etc.).
As an alternative to removing and/or inserting battery pack 150 from below rear portion 110, battery pack 150 may be removed and/or inserted from above rear portion 110. In this case, each piston rod 354 extends vertically upward out of cylinder barrel 352, to lift battery pack 150 vertically upward and out of rear portion 110 by virtue of the couplings between battery pack 150 and attachment points 356. Once exposed to the external environment above rear portion 110, battery pack 150 may be coupled to a crane or other system, including potentially a mobile battery-swapping system as described elsewhere herein, and decoupled from attachment points 356, to thereby remove battery pack 150 from mobile equipment 100. Once battery pack 150 has been removed, mobile equipment 100 may be moved forward and/or battery pack 150 may be moved away from mobile equipment 100 with the assistance of another system (e.g., crane, mobile battery-swapping system, etc.), to thereby separate mobile equipment 100 and battery pack 150, so that battery pack 150 may be serviced (e.g., recharged, reconditioned, etc.).
As illustrated in
Each horizontal movement element 450 may be operate in synchrony with each other horizontal movement element 450. As each piston rod 454 extends out of cylinder barrel 452 battery pack 150 is gradually slid horizontally across a surface 440 of frame 140 and, with stiffener 146 removed, through rear bumper 114 and onto loading dock 460, by virtue of the couplings between battery pack 150 and attachment points 456, as illustrated in
Conversely, a new or recharged battery pack 150 may be positioned on loading dock 460 near rear bumper 114 and coupled to attachment points 456. Then, as each piston rod 454 contracts into cylinder barrel 452, battery pack 150 is gradually pulled horizontally inward through rear bumper 114 and across surface 440 of frame 140 by virtue of the couplings between battery pack 150 and attachment points 456, until battery pack 150 is seated in a final position in frame 140. Once seated, battery pack 150 may be fixed into position within rear portion 110 via any coupling mechanism (e.g., bolts, screws, etc.). In some embodiments, the movement of the battery pack 150 that is illustrated by
Then, as illustrated in
As illustrated in
Platform 510 may be designed to securely hold and manipulate battery pack 150 during the extraction process. For example, battery pack 150 may be fixed to platform 510 for transport using bolts, clamps, or other fastening mechanisms. To maintain stability and distribute the weight of battery pack 150 effectively, platform 510 may be designed with load distribution features and structural reinforcements that fit the dimensions of battery pack 150. These features minimize flexing or twisting of platform 510 during the lifting process and provide stability while handling battery pack 150. Platform 510 may incorporate control and safety features like limit switches, sensors, or feedback mechanisms to monitor the position, load, and stability of battery pack 150. Additionally, safety mechanisms such as locking mechanisms or fail-safes can be integrated into platform 510 to prevent accidental release or dropping of battery pack 510.
Conversely, a new or recharged battery pack 150 may be mounted in frame 140 using the reverse procedure. In particular, battery pack 150 may be positioned on platform 510 and brought near rear portion 110 by mobile battery-swapping system 500, so as to align battery pack 150 with frame 140, with stiffener 146 removed. Then, mobile battery-swapping system 500 may move towards mobile equipment 100 to insert battery pack 150 into frame 140. Battery pack 150 may be unfastened from platform 510 and/or fastened to frame 140. Finally, mobile battery-swapping system 500 move away from mobile equipment 100, to thereby disengage platform 510 from battery pack 150 and leave battery pack 150 in frame 140 of mobile equipment 100.
In some industrial contexts, battery-powered mobile equipment 100 may operate in remote locations, including off-road locations. It takes significant time for these mobile equipment 100 to travel to a recharging station to recharge their battery packs 150. Electric mobile equipment 100 often operate in demanding and dynamic conditions, requiring continuous usage throughout the day. Accordingly, disclosed embodiments provide a battery pack 150 that is capable of being quickly swapped for a new or recharged battery pack 150 to maintain a constant operation of electric mobile equipment 100 on site.
The battery-swapping assembly may comprise a frame 140 configured to support a battery pack 150. Frame 140 includes a body 144, two arms 142 extending from the body, and a removable stiffener 146 between the rear ends of the two arms 142. Additionally, the battery-swapping assembly may comprise a vertical movement system 300 or horizontal movement system 500 with elements that include a cylinder barrel, a piston rod, and attachment points to enable battery pack 150 to be quickly unloaded from frame 140 and loaded into frame 140. Alternatively or additionally, a mobile battery-swapping system 500 may be provided that is able to exchange battery packs 500 in the field.
The ability to quickly swap battery packs 150, potentially in the field, provides increased productivity. For instance, mobile equipment 100 no longer need to leave a work area or interrupt tasks to find a recharging station. Additionally, mobile equipment 100 is only out of service for as long as it takes to swap battery pack 150, as opposed to being out of service for as long as it takes to recharge battery pack 150, which may be a significant time period.
The preceding detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. The described embodiments are not limited to usage in conjunction with a particular type of machine. Hence, although the present embodiments are, for convenience of explanation, depicted and described as being implemented in an electric mobile equipment, it will be appreciated that it can be implemented in various other types of equipment and machines with batteries, and in various other systems and environments. Furthermore, there is no intention to be bound by any theory presented in any preceding section. It is also understood that the illustrations may include exaggerated dimensions and graphical representation to better illustrate the referenced items shown, and are not considered limiting unless expressly stated as such.