Material handling vehicle charging system with floor mounted charging pad

Abstract

A materials handling vehicle includes a vehicle-side charging contact assembly coupled to a battery, a steerable drive wheel defining a drive wheel track width W, and a pair of load wheels defining a load wheel gap G between the pair of load wheels that is greater than the drive wheel track width W. A charging station includes a pair of floor-side charging contacts configured to transmit charging current to the vehicle-side charging contact assembly. The pair of floor-side charging contacts define an inner contact spacing S1 that is greater than the drive wheel track width W, and an outer contact spacing S2 that is greater than the inner contact spacing S1 and less than the load wheel gap G to allow the steerable drive wheel to pass between the floor-side charging contacts and subsequently allow the pair of load wheels to pass outside of the floor-side charging contacts.

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 047,445 (CRO1924MA), filed on July 2, 2020. Background Technology

[0003] Material handling vehicles are used to move materials into, out of, and throughout a warehouse environment. For example, but not limited to, material handling vehicles include winches, forklifts, hand-driven and electric pallet trucks, and other types of material handling vehicles. Material handling vehicles can be configured as either autonomously navigated vehicles or manually navigated vehicles traversing a warehouse environment. To facilitate partially or fully autonomous navigation, the vehicle can be adapted to be positioned within the environment. That is, the material handling vehicle can be equipped with sensors and processors for positioning, i.e., for determining the vehicle's position and, optionally, its orientation within the environment. The sensors can be configured to detect objects in the environment, and positioning can rely on features extracted from these detected objects. Systems of this type are described, for example, in U.S. Patents prior to their grant publication numbers 2016 / 0090281 and 2016 / 0011595. Summary of the Invention

[0004] According to the subject matter of this disclosure, a material handling vehicle charging system includes a material handling vehicle and a charging station. The material handling vehicle includes a material handling mechanism, a battery, a battery-powered drive mechanism, a vehicle-side charging contact assembly defining a vehicle-side contact profile, a vehicle-side charging circuit connecting the vehicle-side charging contact assembly to the battery, a central drive line extending between the front and rear ends of the material handling vehicle, steerable drive wheels powered to the drive mechanism, and a pair of load wheels positioned on opposite sides of the central drive line. The steerable drive wheels are aligned with the central drive line and define a drive wheel track width W. The pair of load wheels are positioned on opposite sides of the central drive line and define a load wheel gap G between the pair of load wheels that is greater than the drive wheel track width W. The charging station includes a floor-mounted charging plate assembly, a battery charger, and a floor-side charging circuit connecting the floor-mounted charging plate assembly to the battery charger. The floor-mounted charging plate assembly includes a pair of floor-side charging contacts defining a floor-side contact profile complementary to the vehicle-side contact profile of the vehicle-side charging contact assembly, allowing direct contact transmission of charging current from the floor-side charging contacts to the vehicle-side charging contact assembly. The pair of floor-side charging contacts define an inner contact spacing S1 that is greater than the drive wheel track width W, and an outer contact spacing S2 that is greater than the inner contact spacing S1 and less than the load wheel clearance G, so as to allow the steerable drive wheels to pass between the pair of floor-side charging contacts while the vehicle is moving along the central drive line, and subsequently allow the pair of load wheels to pass outside the pair of floor-side charging contacts.

[0005] According to one embodiment of this disclosure, a material handling vehicle charging system includes a material handling vehicle and a charging station. The material handling vehicle includes a material handling mechanism, a battery, a battery-powered drive mechanism, a vehicle-side charging contact assembly defining a vehicle-side contact profile, and a vehicle-side charging circuit connecting the vehicle-side charging contacts to the battery. The charging station includes a floor-mounted charging plate assembly, a battery charger, and a floor-side charging circuit connecting the floor-mounted charging plate assembly to the battery charger. The floor-mounted charging plate assembly includes a mounting platform, a multi-directional charging plate mounted to the mounting platform, and a pair of floor-side charging contacts carried by the multi-directional charging plate. The floor-side charging contacts define a floor-side contact profile complementary to the vehicle-side contact profile of the vehicle-side charging contact assembly, allowing direct contact transmission of charging current from the floor-side charging contacts to the vehicle-side charging contact assembly. The multi-directional charging plate includes a charging plate coverage area that is rotationally symmetrical about a rotational mounting axis orthogonal to a mounting plane defined by the mounting platform at multiple mounting locations.

[0006] According to another embodiment of this disclosure, a material handling vehicle charging station includes a floor-mounted charging plate assembly, a battery charger, and a vehicle-side charging circuit connecting the floor-mounted charging plate assembly to the battery charger. The floor-mounted charging plate assembly includes a pair of floor-side charging contacts defining a floor-side contact profile (configured to be complementary to the vehicle-side contact profile of the target material handling vehicle) to allow direct contact transmission of charging current from the floor-side charging contacts to the vehicle-side charging contact assembly. The pair of floor-side charging contacts defines an inner contact spacing S1 greater than the drive wheel track width W of the target material handling vehicle, and an outer contact spacing S2 greater than the inner contact spacing S1 and less than the load wheel clearance G of the target material handling vehicle, to allow the steerable drive wheels of the target material handling vehicle to pass between the pair of floor-side charging contacts, and subsequently, a pair of load wheels of the target material handling vehicle to pass outside the pair of floor-side charging contacts.

[0007] According to another embodiment of this disclosure, a material handling vehicle charging station includes a floor-mounted charging plate assembly, a battery charger, and a vehicle-side charging circuit connecting the floor-mounted charging plate assembly to the battery charger. The floor-mounted charging plate assembly includes a pair of floor-side charging contacts defining a floor-side contact profile (configured to be complementary to the vehicle-side contact profile of the target material handling vehicle) to allow direct contact transmission of charging current from the floor-side charging contacts to the vehicle-side charging contact assembly. The floor-mounted charging plate assembly includes a mounting platform and a multi-directional charging plate mounted to the mounting platform. The multi-directional charging plate carries the floor-side charging contacts and includes a charging plate coverage area that is rotationally symmetrical about a rotational mounting axis orthogonal to a mounting plane defined by the mounting platform at multiple mounting locations.

[0008] Although this document describes the concepts of the present disclosure primarily with reference to winch-type material handling vehicles, the concepts herein will have applicability to various types of battery-powered material handling vehicles. Attached Figure Description

[0009] The following detailed description of specific embodiments of this disclosure may be best understood when read in conjunction with the accompanying drawings, wherein similar structures are indicated by similar reference numerals, and wherein:

[0010] Figure 1 A material handling vehicle charging system, comprising a material handling vehicle and a charging station, is schematically described according to one or more embodiments shown and described herein.

[0011] Figure 2 This is a top view of the charging plate of a charging station according to one or more embodiments shown and described herein;

[0012] Figure 3 This is an isometric view of a material handling vehicle charging system according to one or more embodiments shown and described herein;

[0013] Figure 4 A material handling vehicle charging system according to one or more embodiments shown and described herein is illustrated schematically;

[0014] Figure 5 This is a cross-sectional isometric view of a charging station according to one or more embodiments shown and described herein;

[0015] Figure 6 This is an isometric view of the mounting platform of a charging station according to one or more embodiments shown and described herein;

[0016] Figure 7 It is based on one or more embodiments shown and described herein. Figure 6 A side view of an alternative embodiment of the mounting platform;

[0017] Figure 8 It is based on one or more embodiments shown and described herein. Figure 7 A sectional side view of the installation platform taken along line 8-8;

[0018] Figure 9 and Figure 10 Installation steps for a charging station according to one or more embodiments shown and described herein are illustrated; and

[0019] Figure 11 This is a cross-sectional side view of a charging station installed in the warehouse floor according to one or more embodiments shown and described herein. Detailed Implementation

[0020] First refer to Figure 1-4 This illustrates a material handling vehicle charging system that includes a material handling vehicle 100 and a charging station 200.

[0021] The material handling vehicle 100 may include a material handling mechanism 110, a battery 120, a drive mechanism 130 powered by the battery 120, a vehicle-side charging contact assembly 140 defining a vehicle-side contact profile 150, a vehicle-side charging circuit 160 connecting the vehicle-side charging contact assembly 140 to the battery 120, a central drive line 170 extending between the front end 172 and the rear end 174 of the material handling vehicle 100, steerable drive wheels 180 powered to the drive mechanism 130, a pair of load wheels 190 positioned on opposite sides of the central drive line 170, and a charging control unit 184. The material handling mechanism 110 is only... Figure 1 The diagram is schematic, but it can be provided in various forms, depending primarily on the vehicle type. For example, if the material handling vehicle 100 is a winch, the material handling mechanism 110 can be configured as a traction device, hook, latch, etc. If the material handling vehicle 100 is a forklift, or a hand-driven or electric pallet truck, the material handling mechanism 110 can be configured as a pair of material handling forks.

[0022] Material handling vehicle 100 may be a winch with a material handling mechanism 110 in the form of a traction device or other traction assembly configured to pull a load from the rear end 174 of material handling vehicle 100. However, material handling vehicle 100 may be any vehicle including a material handling mechanism capable of moving materials (e.g., forklifts, hand-driven and electric pallet trucks, and other types of material handling vehicles).

[0023] For details, please refer to the following: Figure 4 The steerable drive wheel 180 can be aligned with the central drive line 170, such that the steerable drive wheel 180 is positioned on the central drive line 170. The steerable drive wheel 180 can define a drive wheel track width W. The drive wheel track width W is at least approximately 40 mm. In one embodiment, the drive wheel track width W is approximately 75 mm, but it can vary depending on the vehicle type. In many cases, it is conceivable that the drive wheel track width W is from approximately 40 mm to approximately 160 mm. The steerable drive wheel 180 can be positioned at the head end 172 of the material handling vehicle 100. In an embodiment, the steerable drive wheel 180 can be positioned at the tail end 174 of the material handling vehicle 100.

[0024] Figure 1The drive mechanism 130, schematically shown, is powered to a drivable drive wheel 180 to rotate the drive wheel 180. The drive mechanism 130 can be any known mechanism for causing vehicle motion (e.g., an engine). The drive mechanism 130 is coupled to a battery 120 such that current can be supplied from the battery 120 to the drive mechanism 130, thereby driving the drive mechanism 130.

[0025] Refer again Figure 4 The pair of load wheels 190 can be positioned on opposite sides of the central drive line 170. The material handling vehicle 100 may include any number of load wheels 190 (e.g., four load wheels). The load wheels 190 can be positioned on opposite sides of the central drive line 170 such that load wheels 190 on one side of the central drive line 170 can be positioned adjacent to each other, and load wheels 190 on the other side of the central drive line 170 can also be positioned adjacent to each other. The load wheels 190 can be arranged such that each wheel rotates about a common axis. A pair of load wheels 190 can define a load wheel gap G between the pair of load wheels 190. In other words, the load wheel gap G can be the spacing or distance between the pair of load wheels 190. In embodiments including more than two load wheels 190, the load wheel gap G refers to the distance between the pair of load wheels 190 closest to the central drive line 170.

[0026] refer to Figure 3 and Figure 4 The load wheel clearance G can be greater than the drive wheel track width W. The load wheel clearance G is, for example, from approximately 300 cm to approximately 1600 cm, and particularly can be approximately 500 cm. The pair of load wheels 190 can be positioned at the rear end 174 of the material handling vehicle 100, and the steerable drive wheel 180 can be positioned relative to the pair of load wheels 190 at the front end 172. In an embodiment, the pair of load wheels 190 can be positioned at the front end 172 of the material handling vehicle 100, while the drive wheel 180 is positioned at the rear end 174.

[0027] like Figure 3Specifically illustrated, the vehicle-side charging contact assembly 140 may include a pair of vehicle-side charging contacts 144 defining a vehicle-side contact profile 150, a vehicle-side data transmission contact 188, and a vehicle-side actuator 142 coupled to the vehicle-side charging contacts 144. The vehicle-side charging contacts 144 may be coupled to the battery 120 via a vehicle-side charging circuit 160, wherein the vehicle-side charging contacts 144 are configured to receive current and transmit current to the battery 120 via the vehicle-side charging circuit 160. The vehicle-side actuator 142 may be configured to raise and lower the vehicle-side charging contacts 144 to contact and disengage them from the charging station 200 to selectively control the transmission of current to the battery 120. The vehicle-side charging contact assembly 140 may be positioned at the rear end 174 of the material handling vehicle 100. However, in an embodiment, the vehicle-side charging contact assembly 140 may be positioned at the front end 172 of the material handling vehicle 100. The vehicle-side actuator 142 can lower the vehicle-side charging contact 144 to make contact with a pair of floor-side charging contacts 212 of the floor-mounted charging plate assembly 210, which will be described in more detail herein.

[0028] The vehicle-side charging contact assembly 140 may further include a vehicle-side data transmission circuit 192 (in Figure 1 (Schematally shown in the diagram) a vehicle-side data transmission contact 188 is communicatively connected to a charging control unit 184. The vehicle-side data transmission contact 188 can be positioned between vehicle-side charging contacts 144. The data transmission contact 188 is configured to transmit data to and from the charging station 200. The data transmitted by the transmission contact 188 may include battery data, vehicle data, charging station data, or any combination thereof. Similar to the vehicle-side charging contacts 144, the data transmission contact 188 can be connected to a vehicle-side actuator 142 to raise and lower the data transmission contact 188 as the vehicle-side charging contacts 144 contact and disconnect from the charging station 200.

[0029] Refer again Figure 1-4 The vehicle-side charging circuit 160, which connects the vehicle-side charging contact assembly 140 to the battery 120, can be a plurality of wires configured to transmit current to and from the vehicle-side charging contact assembly 140 and the battery 120. Specifically, the vehicle-side charging circuit 160 can be connected to the vehicle-side charging contact 144 to transmit current to the battery 120. Furthermore, the vehicle-side charging circuit 160 can be connected to the vehicle-side actuator 142 to transmit current from the battery 120 to the vehicle-side actuator 142, thereby actuating the vehicle-side actuator 142 to raise and lower the vehicle-side charging contact 144.

[0030] Material handling cart 100 may further include sensor 186 (only in...) Figure 1(Illustrated schematically) It is communicatively connected to the charging control unit 184. The sensor 186 can send signals to the charging control unit 184 instructing the material handling vehicle 100 and the vehicle-side charging contact 144 to be correctly aligned with the multi-directional charging plate of the charging station 200. The charging control unit 184 can then detect whether the material handling vehicle 100 and the vehicle-side charging contact 144 are correctly aligned with the multi-directional charging plate of the charging station 200, and in response, can activate the vehicle-side actuator 142 to begin charging. The sensor 186 can be a proximity sensor, GPS sensor, etc., to determine the location of the material handling vehicle 100. The proximity sensor can include, for example, an inductive proximity sensor, a capacitive proximity sensor, an ultrasonic proximity sensor, etc.

[0031] Special Reference Figure 1 The vehicle control system 112 can be communicatively connected to the charging control unit 184 and the drive mechanism 130. The vehicle control system 112 can guide the material handling vehicle 100 by providing signals to the drive mechanism 130, thereby moving and manipulating the drive wheels 180. The vehicle control system 112 can be communicatively connected to a master vehicle controller 114, which provides signals to the vehicle control system 112 indicating the position where the vehicle control system 112 should guide the vehicle 100. The master vehicle controller 114 can be communicatively connected to multiple material handling vehicles 100 to coordinate the movement of the multiple material handling vehicles 100 throughout the warehouse. The vehicle control system 112 can guide the material handling vehicles 100 to perform tasks, such as moving materials throughout the environment. The charging control unit 184 can provide signals to the vehicle control system 112 indicating the charge level in the battery 120 of the material handling vehicle 100. The vehicle control system 112 can send a signal indicating the charge level in the battery 120 to the main vehicle controller 114, and the main vehicle controller 114, in response, can send a signal indicating the location of the charging station 200 to the vehicle control system 112. The location of the charging station 200 can be the nearest unoccupied charging station 200. The vehicle control system 112 can then modify the guidance of the material handling vehicle 100 based on the signal received from the main vehicle controller 114. In response to the signal from the main vehicle controller 114, the vehicle control system 112 can provide a signal to the drive mechanism 130 to guide the material handling vehicle 100 to the nearest charging station 200.

[0032] Refer again Figure 1-4The charging station 200 may include a floor-mounted charging panel assembly 210, a battery charger 220, and a floor-side charging circuit 230 connecting the floor-mounted charging panel assembly 210 to the battery charger 220. In an embodiment, the charging station 200 includes a circuit breaker box 224 connected between the battery charger 220 and the floor-mounted charging panel assembly 210, such that the circuit breaker box 224 can selectively disconnect current from the battery charger 220 to the floor-mounted charging panel assembly 210. The floor-mounted charging panel assembly 210 may include a pair of floor-side charging contacts 212 defining a floor-side contact profile 214, and a pair of floor-side data transmission contacts 226. The floor-side contact profile 214 may complement the vehicle-side contact profile 150 of the vehicle-side charging contact assembly 140, allowing direct contact transmission of charging current from the floor-side charging contacts 212 to the vehicle-side charging contact assembly 140.

[0033] refer to Figure 3 and Figure 4 A pair of floor-side charging contacts 212 define an inner contact spacing S1 and an outer contact spacing S2. The inner contact spacing S1 is the distance between the inner edges 213 of each of the pair of floor-side charging contacts 212. The inner contact spacing S1 is at least approximately 15 mm longer than the drive wheel track width W. The inner contact spacing S1 ranges from approximately 50 mm to approximately 400 mm, and is particularly likely to be approximately 100 mm. The outer contact spacing S2 is the distance between the outer edges 215 of each of the pair of floor-side charging contacts 212. The outer contact spacing S2 is at least approximately 70 mm longer than the inner contact spacing S1. The outer contact spacing S2 ranges from approximately 120 mm to approximately 500 mm, and is particularly likely to be approximately 200 mm. Therefore, the outer contact spacing S2 is greater than the inner contact spacing S1. Additionally, the load wheel clearance G is at least approximately 20 mm longer than the outer contact spacing.

[0034] refer to Figure 2-4 The floor-side charging contact 212 is supported by a multi-directional charging plate 260. The floor-side charging contact 212 includes a positive floor-side contact 217 and a negative floor-side contact 218, which are spaced apart and positioned on opposite sides of the floor-side contact gap to define the contact inner distance S1. The vehicle-side charging contact 144 includes a positive vehicle-side contact 145 and a negative vehicle-side contact 146. The vehicle-side charging contacts 144 are spaced apart such that the vehicle-side contact profile 150 overlaps with the floor-side contact profile 214, such that when the vehicle-side charging contact 144 is lowered by the vehicle-side actuator 142, the vehicle-side charging contact 144 contacts the floor-side charging contact 212.

[0035] The multi-directional charging pad 260 may include a direction indicator 270 oriented along a main direction. The positive floor-side contact 217 and the negative floor-side contact 218 are located on opposite sides of a travel line defined by a central drive line 170 extending along the main direction between the positive floor-side contact 217 and the negative floor-side contact 218. As described above, the electrode properties of the vehicle-side charging contact 144 of the vehicle-side charging contact assembly 140 must match the electrode properties of the floor-side charging contact 212 for proper charging. Specifically, the positive floor-side contact 217 must contact the positive vehicle-side contact 145, while the negative floor-side contact 218 contacts the negative vehicle-side contact 146 to provide charging current to the battery 120. Thus, the direction indicator 270 can indicate the direction in which the material handling vehicle 100 must travel to align the positive vehicle-side contact 145 with the positive floor-side contact 217 and the negative vehicle-side contact 146 with the negative floor-side contact 218. In this way, the charging system according to this disclosure can be configured to ensure that a vehicle to be charged approaches the charging station 200 from the correct direction, thereby ensuring that the electrode properties of the contacts of the vehicle-side charging contact assembly 140 match the electrode properties of the floor-side charging contacts 212 for proper charging. The multi-directional charging pad 260 may include any number of direction indicators 270 (e.g., a pair of direction indicators 270). One direction indicator 270 may be positioned at the entrance side 221 of the space between the floor-side charging contacts 212, and the other at the exit side 223 of the space between the floor-side charging contacts 212. Specifically, in embodiments including a pair of direction indicators 270, one may be positioned at the entrance side 221 and the other at the exit side 223.

[0036] The charging plate 260 may include an additional indicator in the form of a recess within the charging plate 260. The charging plate 260 further includes a polarity indicator 271 and a mounting indicator 272. The polarity indicator 271 is configured to indicate the polarity of each of a pair of floor-side charging contacts 212. Specifically, one of the polarity indicators 271 may provide a "+" sign to indicate a positive charge on the floor-side charging contact 212 adjacent to that polarity indicator 271, and the other polarity indicator 271 may provide a "-" sign to indicate a negative charge on the floor-side charging contact 212 adjacent to that polarity indicator 271. The mounting indicator 272 may be in the shape of a crane hook and is configured to indicate a threaded hole for a crane lug adjacent to the mounting indicator 272. The threaded hole may be located below the pair of floor-side charging contacts 212.

[0037] The size and position of the pair of floor-side charging contacts 212 can be configured such that the inner spacing S1 of the contacts is greater than the drive wheel track width W. Similarly, the size and position of the pair of floor-side charging contacts 212 can be configured such that the outer spacing S2 of the contacts is less than the load wheel clearance G. When the vehicle moves along the central drive line 170, the smaller outer spacing S2 of the contacts than the load wheel clearance G allows the steerable drive wheel 180 to pass between the pair of floor-side charging contacts 212, and a pair of load wheels 190 to pass outside the pair of floor-side charging contacts 212.

[0038] refer to Figure 1 , Figure 3 and Figure 4 A pair of floor-side data transmission contacts 226 are carried by a multi-directional charging plate 260 and can be positioned between floor-side charging contacts 212. The pair of floor-side data transmission contacts 226 are configured to transmit data to and from the material handling vehicle 100. The floor-side data transmission contacts 226 are configured to contact vehicle-side data transmission contacts 188. When the vehicle-side data transmission contact 188 contacts the floor-side data transmission contacts 226, the vehicle-side data transmission contact 188 and the floor-side data transmission contacts 226 define complementary contact profiles to facilitate data transmission between the charging station 200 and the material handling vehicle 100. The vehicle-side data transmission contact 188 transmits data from the material handling vehicle 100 to the pair of floor-side data transmission contacts 226. The data transmitted by the transmission contacts 226 may include battery data, vehicle data, charging station data, or any combination thereof. Although the data transmission contact 226 can be used to transmit data between the charging station 200 and the material handling vehicle 100, the data can be transmitted alternatively or through the vehicle control system 112 in addition to the data transmission contact.

[0039] Now for reference Figure 5 and Figure 6The floor-mounted charging panel assembly 210 may include a multi-directional charging panel 260 and a mounting platform 240 configured to receive the charging panel 260. Specifically, the mounting platform 240 may be configured as a can such that the charging panel 260 is received within the mounting platform 240 to form a lid portion of the mounting platform can. The charging panel 260 may be mounted onto the mounting platform 240. The multi-directional charging panel 260 carries floor-side charging contacts 212 and includes a charging panel cover area 262 that is rotationally symmetric about a rotational mounting axis 244 orthogonal to a mounting plane defined by an edge 247 of the mounting platform 240 at multiple mounting positions. The charging panel cover area 262 may be rotationally symmetric through at least four rotational mounting positions. For example, the multi-directional charging panel 260 may be rectangular or circular with appropriately positioned mounting holes 242 to allow the charging panel 260 to be oriented in different locations. However, the multi-directional charging panel 260 may have any shape, such as triangular, pentagonal, hexagonal, heptagonal, etc. The charging plate 260 may have a number of positions equal to the number of sides of the charging plate 260.

[0040] The floor-mounted charging panel assembly 210 may include mounting hardware 216. Mounting hardware 216 is configured to attach the charging panel 260 to the mounting platform 240. Mounting hardware 216 may be fasteners such as bolts and nuts, rivets, screws, etc. However, in embodiments, the mounting platform 240 may be attached to the charging panel 260 via welding, epoxy resin, adhesive, etc.

[0041] Mounting platform 240 may include a plurality of mounting holes 248 complementary to the mounting holes 242 in charging plate 260. The plurality of mounting holes 248 and mounting holes 242 may be arranged such that mounting hardware 216 can be inserted through the mounting holes 248 and mounting holes 242. Mounting hardware 216 may be used to secure the multi-directional charging plate 260 to mounting platform 240 at multiple mounting locations around a rotational mounting axis 244 via the complementary mounting holes 248 and mounting holes 242. In this way, the multi-directional charging plate 260 can be mounted to mounting platform 240 at multiple different rotational positions. The number of rotational positions may be equal to the number of mounting holes 242. This allows the installer to position the charging plate 260 and the floor-side charging contacts 212 carried thereon in an optimal rotational direction. For example, when best approaching charging station 200 from a particular direction, charging plate 260 may be rotatably oriented to ensure proper alignment of vehicle-side charging contacts 144 of vehicle-side charging contact assembly 140 with floor-side charging contacts 212 of charging station 200. This is particularly ideal in applications where the electrode properties of the vehicle-side charging contacts 144 of the vehicle-side charging contact assembly 140 must match the electrode properties of the floor-side charging contacts 212 for proper charging. The aforementioned mounting arrangement also allows the installer to orient the contact spacing S1 so that the drive wheels 180 of the nearby material handling vehicle 100 can easily pass between the floor-side charging contacts 212.

[0042] The mounting platform 240 may include an upright receiving portion 280, a drain pipe 282 opposite to the upright receiving portion 280, a plurality of peripherally extending stabilizing devices 284 extending from the periphery of the mounting platform 240, and a hole 286 extending through the mounting platform 240 in a direction radially outward from the rotational mounting axis 244. The mounting platform 240 is configured to receive a charging plate 260, wherein the charging plate 260 is coplanar with the end edge 281 of the upright receiving portion 280 of the mounting platform 240. The mounting platform 240 is configured to receive the charging plate 260 such that the charging plate 260 can be mounted to the mounting platform 240 so as to be coplanar with the travel surface of the warehouse floor 300 (e.g., Figure 9-11 (As shown). Specifically, the mounting platform 240 is configured to be connected to the warehouse floor 300, wherein the end edge 281 of the upright receiving portion 280 is coplanar with the warehouse floor 300.

[0043] Hole 286 is configured to receive ground-side charging circuit 230, thereby connecting from battery charger 220 to ground-side charging contact 212 (e.g. Figure 1 (Schematic illustration). Drain pipe 282 may extend from mounting platform 240 parallel to the rotational mounting axis 244. Drain pipe 282 may be in fluid communication with the interior of mounting platform 240, so that fluid entering mounting platform 240 through hole 286 or upright receiving portion 280 may be discharged from mounting platform 240 through drain pipe 282.

[0044] Multiple stabilizing devices 284 can exist in various forms. For example, but not as a limitation, stabilizing device 284 can exist in a folded scalloped shape (e.g., Figure 5 and Figure 6 As shown), or in the form of angled rods (such as...). Figure 7 and Figure 8 (As shown). In an embodiment where the stabilizing device 284 is a folded scalloped shape, multiple stabilizing devices 284 extend radially outward from the rotational mounting axis 244 and may be circular (including a circular surface). In an embodiment where the stabilizing device 284 is an angled rod, multiple stabilizing devices 284 include rods extending obliquely from the mounting platform 240 and heads coupled to the rods opposite the mounting platform 240. The heads may be circular. However, in embodiments, the heads may include any shape.

[0045] In any case, the stabilizing devices should be designed to enhance the extent to which the mounting platform 240 and the remainder of the floor-mounted charging pad assembly 210 can be embedded in the warehouse floor using concrete or other similar materials. Multiple stabilizing devices 284 can increase the surface area of ​​the mounting platform 240 in contact with the material it is embedded in. This increased surface area increases the stability of the mounting platform 240 within the embedded material. In other words, the multiple stabilizing devices 284 grip their embedded material to stabilize the mounting platform 240 when subjected to external forces, such as forces from a vehicle positioned on the charging pad 260. Furthermore, the multiple stabilizing devices 284 may include an indicating stabilizing device 285 that is visually distinct from the other multiple stabilizing devices 284 (e.g., ...). Figure 6 (As shown). The visually distinct stabilizing devices 285 may be triangular, including a leading edge 287. The leading edge 287 is configured to indicate the orientation of the mounting platform 240 during installation. Since the charging plate 260 must be oriented relative to the direction of travel of the material handling vehicle 100, it is desirable to provide an indicator for orienting the charging plate 260 during installation. In the illustrated embodiment, a pair of visually distinct stabilizing devices 285 are provided on opposite sides of the mounting platform 240. These visually distinct stabilizing devices 285 can be used to correctly orient the plurality of mounting holes 242 in the mounting platform 240 to help ensure that the charging plate 260 is correctly oriented when secured to the mounting platform 240.

[0046] Refer again Figure 5 and Figure 6 The charging station 200 may include a conduit 241 extending from the mounting platform 240, and a charging conductor 236 extending from the floor-side charging contact 212 through the mounting platform 240 and the conduit 241 to the floor-side charging circuit 230 of the charging station 200.

[0047] refer to Figure 1 and Figure 5 The charging conductor 236 can be connected to the floor-side charging contact 212 to provide current to the floor-side charging contact 212. The charging conductor 236 can be connected to the floor-side charging contact 212 such that one of the floor-side charging contacts 212 can be a positive charging contact, and the other can be a negative charging contact. The end of the charging conductor 236 opposite to the floor-side charging contact 212 can be connected to the battery charger 220, allowing current to flow from the battery charger 220 through the charging conductor 236, and the charging conductor 236 can transfer current from the battery charger 220 to the floor-side charging contact 212. The charging conductor 236 can also transmit data from the data transmission contact 226 to the battery charger 220. The battery charger 220 can be communicatively connected to the main vehicle controller 114, allowing the battery charger 220 to transmit data from the data transmission contact 226 to the main vehicle controller 114.

[0048] Now for reference Figure 9-11 The installation of charging station 200 will be described. A trench 302 can be formed within a warehouse floor 300 by removing a portion of the warehouse floor 300. The warehouse floor 300 can be made of, for example, concrete. An installation platform 240 and a pipe 241 can then be positioned within the trench 302. The installation platform 240 can be positioned at an end 304 of the trench 302, wherein a drain pipe 282 extends downward from the installation platform 240 away from the warehouse floor 300. The installation platform 240 can be oriented using visually distinct stabilizing devices 285 to position the installation platform 240 relative to, for example, the travel path of a material handling vehicle 100. The pipe 241 can be positioned such that it extends from the installation platform 240 along the trench 302. A charging conductor 236 of the floor-side charging circuit 230 can extend through the pipe 241 into the installation platform 240. The trench 302 can be filled with a filler material (e.g., gravel) to extend around the installation platform 240 and the pipe 241. The filler material allows fluids that may flow around or through the mounting platform 240 to drain. A drain pipe 282 can extend into the filler material to remove fluids from the mounting platform 240 and away from the pipe 241. Afterward, the warehouse floor 300 can be placed back on top of the filler material.

[0049] Once the mounting platform 240 is positioned in the trench 302, the charging conductor 236 extending into the mounting platform 240 can be coupled to the floor-side charging contacts 212. The charging board 260 can then be coupled to the mounting platform 240. By aligning the mounting holes 242 on the charging board 260 with the mounting holes 248 on the mounting platform 240, the charging board 260 can be oriented relative to the mounting platform 240 in one of several rotational positions. The charging board 260 can then be secured to the mounting platform 240 via mounting hardware 216.

[0050] In order to define and describe the concepts and scope of this disclosure, it should be noted that "warehouse" includes any indoor or outdoor industrial site in which material handling vehicles transport goods, including but not limited to indoor or outdoor industrial sites primarily used for storing goods, such as those sites with multi-tiered shelving arranged in aisles, and manufacturing sites used for transporting goods around the site by material handling vehicles during one or more manufacturing processes.

[0051] It should be noted that the descriptions herein of components of this disclosure that are “configured” in a particular manner (to embody a particular property or function in a particular way) are structural descriptions, not descriptions of their intended use. More specifically, the manner in which components are “configured” herein refers to the existing physical state of the components and, in itself, is considered an explicit description of the structural features of the components.

[0052] The subject matter of this disclosure has been described in detail and with reference to specific embodiments therein. Even where specific elements are shown in each of the accompanying drawings, it should be noted that the various details disclosed herein should not be construed as implying that such details relate to elements of essential components of the various embodiments described herein. Furthermore, it will be apparent that modifications and variations are possible without departing from the scope of this disclosure, including but not limited to the embodiments defined in the appended claims. More specifically, although some aspects of this disclosure are defined herein as preferred or particularly advantageous, it is contemplated that this disclosure is not necessarily limited to these aspects.

[0053] It should be noted that one or more of the following claims use the term "wherein" as a transitional word. For the purposes of defining the invention, it should be noted that this term is introduced in the claims as an open transitional word, used to introduce a description of a series of features of the structure, and should be interpreted in a similar manner to the more commonly used open prepositional term "comprising".

Claims

1. A materials handling vehicle charging system comprising a materials handling vehicle and a charging station, characterized in that : The materials handling vehicle includes a materials handling mechanism, a battery, a drive mechanism powered by the battery, a vehicle-side charging contact assembly defining a vehicle-side contact profile, a vehicle-side charging circuit coupling the vehicle-side charging contact assembly to the battery, a central drive line extending between a head end and a tail end of the materials handling vehicle, a steerable drive wheel power coupled to the drive mechanism, and a pair of load wheels positioned on opposite sides of the central drive line; The steerable drive wheel is aligned with the central drive line and defines a drive wheel track width W; The pair of load wheels are positioned on opposite sides of the central drive line and define a load wheel gap G between the pair of load wheels that is greater than the drive wheel track width W; The charging station includes a floor-mounted charging pad assembly, a battery charger, and a floor-side charging circuit coupling the floor-mounted charging pad assembly to the battery charger; The floor-mounted charging pad assembly includes a pair of floor-side charging contacts defining a floor-side contact profile complementary to the vehicle-side contact profile of the vehicle-side charging contact assembly to enable direct contact transmission of charging current from the floor-side charging contacts to the vehicle-side charging contact assembly; And The pair of floor-side charging contacts define an inner contact spacing S1 that is greater than the drive wheel track width W, and an outer contact spacing S2 that is greater than the inner contact spacing S1 and less than the load wheel gap G to allow the steerable drive wheel to pass between the pair of floor-side charging contacts and subsequently allow the pair of load wheels to pass outside of the pair of floor-side charging contacts with the materials handling vehicle moving along the central drive line.

2. The material handling vehicle charging system of claim 1, wherein : The floor-mounted charging pad assembly includes a mounting platform and a multidirectional charging pad mounted on the mounting platform; and The multidirectional charging pad carries the floor-side charging contacts and includes a charging pad footprint that is rotationally symmetric about a rotational mounting axis normal to a mounting plane defined by the mounting platform through at least four rotational mounting positions.

3. The material handling vehicle charging system of claim 1, wherein : The floor-mounted charging pad assembly includes a mounting platform and a multidirectional charging pad mounted on the mounting platform; The floor-side charging contacts are carried by the multidirectional charging pad and include a positive floor-side contact and a negative floor-side contact spaced apart to define the inner contact spacing S1; and The multidirectional charging pad includes a directional indicator oriented along a primary direction and the positive floor-side contact and the negative floor-side contact are positioned on opposite sides of a travel line extending between the positive floor-side contact and the negative floor-side contact along the primary direction.

4. The material handling vehicle charging system of claim 1, wherein, The floor-mounted charging pad assembly includes a mounting platform configured to receive a charging pad; The mounting platform is configured as a mounting platform can and the charging pad forms a cover portion of the mounting platform can; and The charging station includes a conduit extending from the mounting platform can and a charging conductor extending from the floor-side charging contacts through the mounting platform can and the conduit to the floor-side charging circuit of the charging station.

5. The material handling vehicle charging system of claim 1, wherein : The floor-mounted charging pad assembly includes a mounting platform configured to receive a charging pad; The mounting platform includes an upstanding receiving portion; And The mounting platform is configured to receive the charging pad, wherein the charging pad is coplanar with an end edge of the upstanding receiving portion of the mounting platform.

6. The material handling vehicle charging system of claim 1, wherein, the floor mounted charging pad assembly includes a mounting platform configured to receive a charging pad; and the mounting platform is configured to receive the charging pad such that the charging pad can be mounted to the mounting platform so as to be coplanar with a travel surface of a warehouse floor.

7. The material handling vehicle charging system of claim 1, wherein : the floor mounted charging pad assembly includes a mounting platform configured to receive a charging pad; the mounting platform includes a plurality of peripherally extending stabilizing devices; the floor mounted charging pad assembly includes mounting hardware; the mounting platform and charging pad include a plurality of complementary mounting holes arranged such that mounting hardware can be used to secure the charging pad to the mounting platform through the complementary mounting holes; and the plurality of peripherally extending stabilizing devices includes a stabilizing device that is visually distinct from the remaining plurality of stabilizing devices.

8. The material handling vehicle charging system of claim 1, wherein : the steerable drive wheel is positioned at a head end of the material handling vehicle; the pair of load wheels are positioned at a tail end of the material handling vehicle; the vehicle side charging contact assembly is positioned at the tail end of the material handling vehicle; and the material handling vehicle is a hoist configured to pull a load from the tail end of the material handling vehicle.

9. The material handling vehicle charging system of claim 1, wherein : the material handling vehicle further includes a vehicle side data transfer contact and a vehicle side data transfer circuit; the floor mounted charging pad assembly further includes a floor side data transfer contact positioned between the floor side charging contacts; and the vehicle side data transfer contact and the floor side data transfer contact define complementary contact profiles to facilitate data transfer between the charging station and the material handling vehicle.

10. A materials handling vehicle charging system comprising a materials handling vehicle and a charging station, characterized in that : the material handling vehicle includes a material handling mechanism, a battery, a drive mechanism powered by the battery, a vehicle side charging contact assembly defining a vehicle side contact profile, and a vehicle side charging circuit coupling the vehicle side charging contact assembly to the battery; the charging station includes a floor mounted charging pad assembly, a battery charger, and a floor side charging circuit coupling the floor mounted charging pad assembly to the battery charger; the floor mounted charging pad assembly includes a mounting platform, a multidirectional charging pad mounted to the mounting platform, and a pair of floor side charging contacts carried by the multidirectional charging pad; the mounting platform is configured to receive the charging pad such that the charging pad can be mounted to the mounting platform so as to be coplanar with a travel surface of a warehouse floor; the floor side charging contacts define a floor side contact profile that is complementary to the vehicle side contact profile of the vehicle side charging contact assembly to enable direct contact transfer of charging current from the floor side charging contacts to the vehicle side charging contact assembly; and the multidirectional charging pad includes a charging pad footprint that is rotationally symmetric about a rotational mounting axis normal to a mounting plane defined by the mounting platform at a plurality of mounting positions.

11. A materials handling vehicle charging station comprising a floor mounted charging pad assembly, a battery charger, and a floor side charging circuit coupling the floor mounted charging pad assembly to the battery charger, characterized in that : The floor mounted charging pad assembly includes a pair of floor side charging contacts that define a floor side contact profile configured to complement a vehicle side contact profile of a target materials handling vehicle to enable direct contact transmission of charging current from the floor side charging contacts to the vehicle side charging contact assembly; and The pair of floor side charging contacts define an inner contact spacing SI that is greater than a drive wheel track width W of the target materials handling vehicle, and an outer contact spacing S2 that is greater than the inner contact spacing SI and less than a load wheel clearance G of the target materials handling vehicle to allow steerable drive wheels of the target materials handling vehicle to pass between the pair of floor side charging contacts and subsequently allow a pair of load wheels of the target materials handling vehicle to pass outside of the pair of floor side charging contacts The pair of floor side charging contacts define an inner contact spacing SI that is greater than a drive wheel track width W of the target materials handling vehicle, and an outer contact spacing S2 that is greater than the inner contact spacing SI and less than a load wheel clearance G of the target materials handling vehicle to allow steerable drive wheels of the target materials handling vehicle to pass between the pair of floor side charging contacts and subsequently allow a pair of load wheels of the target materials handling vehicle to pass outside of the pair of floor side charging contacts 12. A materials handling vehicle charging station comprising a floor mounted charging pad assembly, a battery charger, and a vehicle side charging circuit coupling the floor mounted charging pad assembly to the battery charger, characterized by : The floor mounted charging pad assembly includes a pair of floor side charging contacts that define a floor side contact profile configured to complement a vehicle side contact profile of a target materials handling vehicle to enable direct contact transmission of charging current from the floor side charging contacts to the vehicle side charging contact assembly; The floor mounted charging pad assembly includes a mounting platform and a multidirectional charging pad mounted to the mounting platform; The mounting platform is configured to receive a charging pad such that the charging pad can be mounted to the mounting platform so as to be coplanar with a travel surface of a warehouse floor; and The multidirectional charging pad carries the floor side charging contacts and includes a charging pad footprint that is rotationally symmetric about a rotational mounting axis that is normal to a mounting plane defined by the mounting platform at a plurality of mounting positions.

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