Battery assembly

Abstract

A battery assembly is provided that includes a battery pack including an outer battery pack housing and a base electrical connector, and a service box. The service box includes an outer service box housing, an intermediate electrical connector, and an end electrical connector. The intermediate electrical connector is electrically coupled to the end electrical connector, and the intermediate electrical connector and the base electrical connector are configured to reversibly connect to each other. The battery pack case is detachably attached to the service box case to form a single unit in which the base electrical connector is connected to the intermediate electrical connector and the end electrical connectors are exposed to the outside to allow the battery pack to be electrically coupled to an external device via the service box. The end electrical connector is mounted on the service box housing such that the end electrical connector is movable relative to the service box housing in a direction substantially perpendicular to a connection direction of the end electrical connector. A battery replacement system is provided that includes a battery assembly and an external device including a battery compartment configured to removably receive the battery assembly. The battery compartment includes a compartment electrical connector configured to be reversibly connected to an end electrical connector of the battery assembly to electrically couple the battery assembly to an external device. A storage and retrieval system is provided that includes a storage structure and a battery replacement system. A method of servicing a battery assembly is provided.

Description

Technical Field

[0001] The present invention relates to a battery assembly used in a battery replacement system. Background Art

[0002] Some industrial and commercial activities require systems that can store and retrieve large quantities of different products. WO2015019055A1 describes a storage and retrieval system in which stacks of storage containers are arranged within a grid storage structure. The system further includes a remotely operated loading handling device configured to move along tracks located at the top of the grid storage structure. To access the containers within the grid storage structure, the loading handling device is equipped with a container holding device for releasably gripping the containers at the top of the stack and a lifting assembly for raising and lowering the containers.

[0003] Each loading handling device is powered by a rechargeable battery. Typically, the rechargeable battery can be charged in place by driving the loading handling device to a charging station located at the edge of the grid storage structure. When recharging the battery, the loading handling device remains stationary at the charging station. The charging time is a significant cause of downtime for the loading handling device and can be up to approximately several hours.

[0004] To alleviate the problem of charging downtime, the loading handling device can be powered by a replaceable battery pack. When the battery pack of the loading handling device runs out of power, the depleted battery pack is replaced with a fully charged battery pack. Thus, the charging downtime is reduced to the time required to replace the battery pack rather than the time required to charge the battery pack.

[0005] Frequent removal and replacement of the battery pack in the loading handling device can cause wear of the battery pack. The present invention aims to alleviate the problems associated with battery pack wear. Summary of the Invention

[0006] The present invention is defined by the appended claims.

[0007] The present invention provides a battery assembly, which includes: A battery pack, which includes an external battery pack housing and a basic electrical connector; and A service box, which includes an external service box housing, an intermediate electrical connector, and an end electrical connector, wherein the intermediate electrical connector is electrically coupled to the end electrical connector, and the intermediate electrical connector and the basic electrical connector are configured to be reversibly connected to each other; Wherein, the battery pack housing is detachably attached to the service box housing to form a single unit, in which the basic electrical connector is connected to the intermediate electrical connector, and the end electrical connector is exposed to allow the battery pack to be electrically coupled to an external device via the service box; wherein, the end electrical connector is mounted to the service box housing such that the end electrical connector can move relative to the service box housing in a direction substantially perpendicular to the connection direction of the end electrical connector.

[0008] Thus, the service box serves as a "sacrificial interface" between the battery pack and the external device, minimizing wear on the basic electrical connector of the battery pack during the use of the battery pack. Specifically, by arranging the end electrical connector of the battery assembly on the service box, whenever the battery assembly is connected to an external device, the basic electrical connector of the battery pack does not undergo any plugging and unplugging cycles. Therefore, when the end electrical connector needs to be replaced, only the service box needs to be replaced, without having to replace the battery pack itself. Since the time and technical requirements for servicing the battery pack are usually higher than those for simply replacing the service box, the battery assembly of the present invention can be serviced more quickly, more efficiently, and more cost-effectively.

[0009] Another advantage of replacing the service box instead of servicing the battery pack is that the service box reduces the need for transporting the battery pack. Since the battery pack is classified as a dangerous good, its transportation cost is relatively high in order to comply with relevant regulatory requirements. The service box can be easily repaired on-site or transported to another location or supplier for repair. Since the service box is much lighter than the battery pack and is not a dangerous good, the transportation cost is relatively low.

[0010] Spare service boxes can be stored on-site at the storage facility, so that when a faulty service box needs to be replaced, the faulty service box can be replaced with a spare service box. Repairing the service box (such as replacing connectors) is not only relatively simple, but also since the electrical connectors in the service box are not energized, there is no risk of repairing the service box like there is with repairing the battery pack. The battery pack itself does not need to be taken out of service for repair.

[0011] The service box housing can be removed (unloaded) from the battery pack housing to replace or repair the service box.

[0012] The battery pack housing and the service box housing can be rigid, i.e., made of a rigid material. The service box housing can be made of metal, such as a metal plate. Alternatively, the service box can be injection-molded plastic.

[0013] The basic electrical connector can be (directly or indirectly) mounted on the battery pack housing or supported by the battery pack housing (directly or indirectly). The intermediate electrical connector and the end electrical connector can be (directly or indirectly) mounted on the service box housing or supported by the service box housing (directly or indirectly). The end electrical connector can be (directly or indirectly) mounted on the service box housing or supported by the service box housing (directly or indirectly).

[0014] The battery pack housing can be detachably attached to the service box housing so as to prevent the disconnection between the basic electrical connector and the intermediate electrical connector when the battery pack housing is attached to the service box housing.

[0015] The basic electrical connector, the intermediate electrical connector, and the end electrical connector can be power connectors respectively configured to allow power to be transmitted from the battery pack to an external device and / or from the external device to the battery pack via the service box.

[0016] The service box can include a fuse coupled between the intermediate electrical connector and the end electrical connector.

[0017] The connection direction of the end electrical connector can be different from the connection direction of the intermediate electrical connector. The connection direction of the end electrical connector can be substantially perpendicular to the connection direction of the intermediate electrical connector. The intermediate electrical connector can be arranged to connect to the basic electrical connector in a horizontal direction, while the end electrical connector can be arranged to connect to the electrical connector of the external device in a vertical direction. The connection direction of the electrical connector is defined as the direction in which the electrical connector is configured to connect (dock) to the corresponding electrical connector.

[0018] The service box housing can be detachably attached to the battery pack housing by one or more than one fastener, such as screws or nuts and bolts.

[0019] At least one of the battery pack housing and the service box housing can include a flange. The service box housing can be detachably attached to the battery pack housing via the flange.

[0020] The battery pack can include guiding features configured to cooperate with corresponding guiding features of the service box such that the basic electrical connector and the intermediate electrical connector are aligned for connection and such that the battery pack housing and the service box housing are aligned for attachment. The guiding features of the battery pack can be protrusions, while the corresponding guiding features of the service box can be holes or grooves, or vice versa.

[0021] The movement of the end electrical connector relative to the service box housing can be limited to a maximum of a predetermined distance.

[0022] The end electrical connector can include at least one alignment member configured to mate with at least one corresponding alignment feature of an external electrical connector to align the end electrical connector with the external electrical connector, thereby allowing the end electrical connector to be connected to the external electrical connector. The at least one alignment member can include a protrusion or a groove extending in a direction parallel to the connection direction of the end electrical connector.

[0023] The base electrical connector can be mounted on the battery pack housing such that the base electrical connector is movable relative to the battery pack housing in a direction substantially perpendicular to the connection direction of the base electrical connector. The base electrical connector can be restricted to move relative to the battery pack housing by a maximum of a predetermined distance.

[0024] The intermediate electrical connector can be mounted on the service box housing such that the intermediate electrical connector is movable relative to the service box housing in a direction substantially perpendicular to the connection direction of the intermediate electrical connector. The intermediate electrical connector can be restricted to move relative to the service box housing by a maximum of a predetermined distance.

[0025] The base electrical connector and the intermediate electrical connector can be blind mate connectors. The end electrical connector can be a blind mate connector.

[0026] The service box can include a cable assembly that includes one or more cables. The intermediate electrical connector can be electrically coupled to the end electrical connector through one or more cables of the cable assembly. The cable assembly can be housed within the service box housing.

[0027] The battery pack can include a plurality of base electrical connectors. The service box can include a plurality of intermediate electrical connectors and a plurality of end electrical connectors. Each intermediate electrical connector can be electrically coupled to a respective base electrical connector. Each intermediate electrical connector can be configured to reversibly connect to a respective base electrical connector. The battery pack housing can be detachably attached to the service box to form a single unit in which the base electrical connectors are connected to their respective intermediate electrical connectors. Each end electrical connector can be exposed to allow the battery pack to be electrically coupled to an external device via the service box. The plurality of end electrical connectors can include a plurality of connector modules forming a single modular electrical connector.

[0028] At least one of the plurality of base electrical connectors can be a power connector, at least one of the plurality of intermediate electrical connectors can be a power connector, and at least one of the plurality of end electrical connectors can be a power connector to allow power to be transmitted from the battery pack to an external device and / or from the external device to the battery pack via the service box.

[0029] The battery pack may further include a battery management system. At least one of the plurality of base electrical connectors may be a base signal connector electrically coupled to the battery management system, at least one of the plurality of intermediate electrical connectors may be a signal connector, and at least one of the plurality of end electrical connectors may be a signal connector to allow signals to be transmitted from the battery management system to an external device and / or from the external device to the battery management system via the service box.

[0030] The present invention also provides a battery replacement system. The battery replacement system includes the battery assembly defined above and an external device. The external device includes a battery compartment configured to removably receive the battery assembly. The battery compartment may include a compartment electrical connector configured to reversibly connect to the end electrical connector of the battery assembly to electrically couple the battery assembly to the external device. The compartment electrical connector may be a power connector. Once electrically coupled, the battery assembly can supply power to one or more electrical components and / or electronic components of the external device. In the case where there are a plurality of base electrical connectors, a plurality of intermediate connectors, and a plurality of end electrical connectors, the battery compartment may include a plurality of compartment electrical connectors, each configured to reversibly connect to a respective electrical connector of the battery assembly.

[0031] The battery replacement system may further include a robotic arm configured to move the battery assembly into and out of the battery compartment.

[0032] The battery replacement system may further include a battery station. The battery station includes one or more slots configured to removably receive the battery assembly and a charging system for charging the battery assembly. Each slot may include an electrical connector configured to reversibly connect to the end connector of the battery assembly to electrically couple the battery assembly to the charging system. The robotic arm may be further configured to move the battery assembly into and out of the slot and to move the battery assembly between the battery compartment of the external device and the slot of the battery station.

[0033] The battery assembly may have an external battery assembly housing defined by the battery pack housing and the service box housing. The battery assembly may further include one or more positioning members mounted on the battery assembly housing, wherein the positioning member is configured to allow the battery assembly to self-position in the battery compartment when the battery assembly is moved into the battery compartment. The positioning member may extend in a direction parallel to the connection direction of the end connector. The positioning member may include one or more tapered surfaces.

[0034] The battery compartment may be configured to receive the battery assembly in a downward direction. The service box may be detachably attached to the side of the battery pack. The end electrical connector and the compartment electrical connector may be configured to connect in a vertical direction.

[0035] The external device may be a loading handling device for lifting and moving containers arranged in a stack in a storage structure, the storage structure including a track structure, the track structure including a first set of tracks and a second set of tracks, the first set of tracks extending in a first direction and the second set of tracks extending in a second direction, the second direction being substantially perpendicular to the first direction to form a grid pattern that defines a plurality of grid cells above the stack of containers, the loading handling device including: A drive assembly configured to move the loading handling device on the track structure; A container holding device configured to releasably hold a container from above; and A lifting mechanism configured to raise and lower the container holding device.

[0036] The loading handling device may include an external body, and a battery compartment may be exposed to allow a battery assembly to be moved into the battery compartment from a location outside the external body of the loading handling device and to be moved out of the battery compartment to a location outside the external body of the loading handling device.

[0037] The present invention also provides a storage and retrieval system, which includes: A storage structure, which includes: A track structure including a first set of tracks and a second set of tracks, the first set of tracks extending in a first direction and the second set of tracks extending in a second direction, the second direction being substantially perpendicular to the first direction to form a grid pattern that defines a plurality of grid cells; and A plurality of upright members configured to support the track structure from below to define a storage area below the track structure for storing a stack of a plurality of containers below each grid cell; and wherein the storage and retrieval system further includes a battery replacement system as defined above.

[0038] The present invention also provides a method of assembling a battery assembly as defined above. The method includes the following steps: (i) Coupling a battery pack and a service box to connect a base electrical connector to an intermediate electrical connector; and (ii) Attaching a service box housing to a battery pack housing.

[0039] The present invention also provides a method of disassembling a battery assembly as defined above. The method includes the following steps: (i) Removing the service box housing from the battery pack housing; and (ii) Separating the battery pack from the service box to disconnect the connection between the base electrical connector and the intermediate electrical connector.

[0040] The present invention also provides a method for servicing a battery assembly as defined above, wherein the service box of the battery assembly is the first service box. The method includes the following steps: (i) removing the housing of the first service box from the battery pack housing; (ii) separating the first service box from the battery pack to disconnect the connection between the basic electrical connector and the intermediate electrical connector; (iii) coupling a second service box to the battery pack to connect the basic electrical connector to the intermediate electrical connector of the second service box; and (iv) attaching the service box housing of the second service box to the battery pack housing.

[0041] The end connectors of the second service box may experience fewer plugging and unplugging cycles than the end connectors of the first and second service boxes (when the first service box is replaced with the second service box).

[0042] The present invention also provides a method for servicing a battery assembly as defined above. The method includes the following steps: (i) removing the service box housing from the battery pack housing; (ii) separating the service box from the battery pack to disconnect the connection between the basic electrical connector and the intermediate electrical connector; (iii) replacing or repairing at least one component of the service box; (iv) coupling the service box to the battery pack to dock the first basic electrical connector to the electrical connector of the first service box; and (v) attaching the service box housing to the battery pack housing.

[0043] At least one component in step (iii) may include an end electrical connector.

[0044] In either of the above two methods for servicing a battery assembly, step (i) of any one method may be performed after the end connectors have experienced a predetermined number of plugging and unplugging cycles. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] The present invention will now be described by way of example only with reference to the accompanying drawings, wherein: Figure 1 is a schematic perspective view of a grid storage structure and a container arranged within the grid storage structure.

[0046] Figure 2 is Figure 1 a plan schematic view of a track structure on top of the storage structure of

[0047] Figure 3 shows Figure 1 a loading handling device on top of the track structure of the storage structure of

[0048] Figure 4 is a schematic perspective view of a loading processing device, wherein a container holding device is positioned below the bottom of the loading processing device.

[0049] Figure 5 is a schematic perspective view of the loading processing device in which the side of the outer body is omitted to show the container receiving space Figure 4 thereof.

[0050] Figure 6 is a schematic perspective view of the loading processing device in which a container occupies the container receiving space Figure 5 thereof.

[0051] Figure 7 is a perspective view of a battery assembly within a battery compartment of the loading processing device.

[0052] Figure 8 is an exploded view of the battery assembly outside the battery compartment Figure 7 thereof.

[0053] Figure 9 is Figure 6 a schematic perspective view of the loading processing device shown in FIG. , wherein an exemplary area for positioning the battery compartment is marked.

[0054] Figure 10 is a schematic perspective view of an alternative outer body for the loading processing device, which includes corner blocks connected together by horizontal connecting elements and vertical connecting elements to form an open frame structure.

[0055] Figure 11 is a perspective view of a battery assembly including a service box attached to a battery pack.

[0056] Figure 12 is a perspective view of a separate battery pack.

[0057] Figure 13 is a perspective view of a separate service box, wherein a side of the service box coupled to the battery pack is shown.

[0058] Figure 14 is a perspective view of the service box, wherein a side of the service box opposite to the Figure 13 side shown in FIG. is shown.

[0059] Figure 15A is a perspective bottom view of an end connector of the service box.

[0060] Figure 15B is a perspective top view of the end connector.

[0061] Figure 16Is an isometric top view of an electrical connector of a battery compartment for an end connector that connects to a service box.

[0062] Figure 17 Is an isometric view of the interior of a service box without an end connector.

[0063] Figure 18A Is an isometric view of the interior of a service box with an end connector mounted on the outer housing of the service box.

[0064] Figure 18B Shows Figure 18A The same view, where nuts and washers are removed from each alignment pin of the end connector.

[0065] Figure 19 Is an isometric view showing a cable assembly housed in a service box.

[0066] Figure 20 Is at Figure 1 A schematic isometric view of a gantry robot operating above the track structure of the grid storage structure shown.

[0067] Figure 21 Is at Figure 1 A schematic isometric view of an articulated robot operating adjacent to the track structure of the grid storage structure shown.

[0068] Figure 22 Is a schematic isometric view of a battery station including slots for accommodating battery assemblies.

[0069] Figure 23 Is a block diagram showing an exemplary control system of a storage and retrieval system. Detailed Description

[0070] Figure 1 Shows an exemplary storage structure 1 that can be used in a storage and retrieval system to store storage containers 9. The storage structure 1 includes a frame that includes upright members 3 and horizontal members 5, 7 supported by the upright members 3. The horizontal members 5 are parallel to each other and extend parallel to the shown x-axis. The horizontal members 7 are parallel to each other, parallel to the shown y-axis, and extend transversely to the horizontal members 5. The upright members 3 are parallel to each other, parallel to the shown z-axis, and extend transversely to the horizontal members 5, 7. The horizontal members 5, 7 form a grid pattern defining a plurality of grid cells 14. In the shown embodiment, the storage containers 9 are arranged in stacks 11 below the grid cells 14 defined by the grid pattern, with one stack 11 of containers 9 for each grid cell 14.

[0071] Figure 2 Shows a large-scale plan view of a portion of the track structure 13 that forms Figure 1The portion of the storage structure 1 shown and is located on top of the horizontal members 5, 7 of the storage structure 1 shown in FIG. 18. The track structure 13 can be provided by the horizontal members 5, 7 themselves (e.g., formed in or on the surface of the horizontal members 5, 7) or by one or more additional components mounted on top of the horizontal members 5, 7. The shown track structure 13 includes an x-direction track 17 and a y-direction track 19, i.e., a first set of tracks 17 extending in the x direction, and a second set of tracks 19 extending in the y direction and transverse to the tracks 17 in the first set of tracks 17. The tracks 17, 19 define a hole 15 located at the center of the grid cell 14. The size of the hole 15 is designed to allow the storage container 9 located below the grid cell 14 to be lifted and lowered through the hole 15. The x-direction tracks 17 are provided in pairs and separated by a channel 21, and the y-direction tracks 19 are provided in pairs and separated by a channel 23. Other arrangements of the track structure are also possible.

[0072] Figure 3 A plurality of load handling devices 25 moving on top of the storage structure 1 shown in FIG. 18 are shown. The load handling devices 25 (hereinafter referred to as "robots") are provided with sets of wheels to engage with the corresponding x-direction or y-direction tracks 17, 19, so that the robot 25 can travel on the track structure 13 and reach a specific grid cell 14. The shown pairs of tracks 17, 19 separated by the channels 21, 23 allow the robot 25 to occupy (or pass by each other) adjacent grid cells 14 without colliding with each other.

[0073] As Figure 4 shown, the robot 25 includes an outer body 27, and one or more components enabling the robot 25 to perform its intended functions are mounted in or on the outer body 27. These functions can include moving across the storage structure 1 on the track structure 13 and raising or lowering the storage container 9 (e.g., raising or lowering from the stack 11 to the stack 11), so that the robot 25 can retrieve or deposit the storage container 9 at a specific position defined by the grid pattern.

[0074] The shown robot 25 includes a drive assembly, which includes a first set of wheels 29 and a second set of wheels 31. The first set of wheels 29 and the second set of wheels 31 are mounted on the outer body 27 of the robot 25 and enable the robot 25 to move in the x direction and the y direction along the tracks 17 and 19, respectively. Specifically, Figure 4 two wheels 29 are provided on the shorter side of the robot 25 visible in Figure 4Two wheels 31 are provided on the longer side of the robot 25 visible in the figure, and two other wheels 31 are provided on the opposite longer side of the robot 25. The wheels 31 engage with the track 19 and are rotatably mounted on the outer body 27 of the robot 25 to allow the robot 25 to move along the track 19.

[0075] To enable the robot 25 to move on different wheels 29, 31 in the first and second directions, the drive assembly further includes a wheel positioning mechanism (not shown) for selectively engaging the first set of wheels 29 with the first set of tracks 17 or the second set of wheels 31 with the second set of tracks 19. The wheel positioning mechanism is configured to raise and lower the first set of wheels 29 and / or the second set of wheels 31 relative to the outer body 27, thereby enabling the loading handling device 25 to selectively move along the tracks 17, 19 of the storage structure 1 in the first or second direction.

[0076] The wheel positioning mechanism may include one or more linear actuators, rotating components, or other means for raising and lowering at least one set of wheels 29, 31 relative to the outer body 27 of the robot 25 to bring at least one set of wheels 29, 31 into contact with and out of contact with the tracks 17, 19. In some embodiments, only one set of wheels is configured to be raised and lowered, and the act of lowering one set of wheels can effectively lift the other set of wheels off the corresponding track, while the act of raising one set of wheels can effectively lower the other set of wheels into contact with the corresponding track. In other embodiments, both sets of wheels can be raised and lowered, which advantageously means that the outer body 27 of the robot 25 remains substantially at the same height, so the weight of the outer body 27 and the components mounted on the outer body 27 do not need to be lifted and lowered by the wheel positioning mechanism.

[0077] The robot 25 further includes a lifting assembly 33 and a container holding device 37 configured to raise and lower the storage container 9. The illustrated lifting assembly 33 includes four tethers 35 connected to the container holding device 37 at its lower end. The tethers 35 can be in the form of cables, ropes, belts, or any other form of tether having the physical properties required to lift the storage container 9. The container holding device 37 includes a clamping mechanism 39 configured to engage with the features of the storage container 9 to releasably hold the container 9 from above. In the illustrated embodiment, the clamping mechanism 39 includes legs that can be received in corresponding holes 10 in the edge of the storage container 9 and then moved upward to engage with the bottom side of the edge of the storage container 9. The tethers 35 can be wound up or down as needed to raise or lower the container holding device 37. One or more motors or winches or other devices can be provided to effect or control the upward or downward winding of the tethers 35.

[0078] In Figure 5 andFigure 6 In [description], the side portions of the outer body 27 of the robot 25 are omitted so that the interior of the robot 25 can be seen. The shown outer body 27 of the robot 25 has an upper portion 41 and a lower portion 43. The upper portion 41 is configured to house or support one or more operating components (not shown), such as components of the lifting assembly 33 (e.g., a motor), a wireless communication component, a robot control system for controlling the operation of the robot 25 (including one or more robot controllers), etc. The lower portion 43 is disposed below the upper portion 41. The lower portion 43 is open to the outside at the bottom and defines a container receiving space 45 for receiving at least a portion of the storage container 9 that has been lifted into the container receiving space 45 by the lifting assembly 33. Figure 5 The container receiving space 45 is shown before being occupied by the storage container 9, while Figure 6 the container receiving space 45 is shown after being occupied by the storage container 9. The size of the container receiving space 45 is designed such that the storage container 9 can be fully inserted into the interior of the space 45, enabling the robot 25 to move across the track structure 13 at the top of the storage structure 1, and the bottom side of the storage container 9 will not get stuck on the track structure 13 or another part of the storage structure 1. When the robot 25 reaches its intended destination, the lifting assembly 33 controls the tether 35 to lower the container holding device 37 and the corresponding storage container 9 from the space 45 to the intended position. The intended position can be a stack 11 of storage containers 9 or an exit point of the storage structure 1 (or, if the robot 25 has moved and picked up a storage container 9 to store the storage container 50 in the storage structure 1, an entry point of the storage structure 1). Although in the shown embodiment, the upper portion 41 and the lower portion 43 are separated by a physical separator, in other embodiments, the upper portion 41 and the lower portion 43 may not be physically separated by a specific component or part of the outer body 27 of the robot 25. The up-and-down configuration of the robot 25 enables the robot 25 to occupy only a single grid cell 14 of the track structure 13 of the storage system 1.

[0079] In an alternative embodiment, the container receiving space 45 of the robot 25 may not be within the outer body 27 of the robot 25. For example, the container receiving space 49 may instead be adjacent to the outer body 27 of the robot 25, such as in a cantilever arrangement, with the weight of the outer body 27 of the robot 25 balancing the weight of the container 9 to be lifted. In such an embodiment, the framework or arm of the lifting assembly 33 may protrude horizontally from the outer body 27 of the robot 25, and the tether 35 may be arranged at respective positions on the protruding framework / arm and configured to be raised and lowered from these positions to raise and lower the storage container 9 into and out of the container receiving space 45 adjacent to the outer body 27.

[0080] Figure 7 and Figure 8Shown is a battery assembly 100 for powering a robot 25 and a battery compartment 80 of the robot 25 for receiving the battery assembly 100. Figure 7 Shown is the battery assembly 100 within the battery compartment 80, Figure 8 and is an exploded view of the battery assembly 100 outside the battery compartment 80. Figure 7 The battery compartment 80 includes side walls 84 and a top opening, the side walls defining a substantially cubic battery receiving space, the top opening for receiving the battery in a downward direction in the battery receiving space. The battery compartment 80 may further include a base (from which the side walls 84 extend) to support the bottom of the battery assembly 100, or support may be provided by another part of the robot 25. The battery compartment 80 further includes an electrical connector 82 for connecting (docking) to an exposed electrical connector 152 of the battery assembly 100 when the battery assembly 100 is inserted into the battery compartment 80. Thereafter, the electrical connector 152 of the battery assembly 100 will be referred to as the "end connector" 152, and the electrical connector 82 of the battery compartment 80 will be referred to as the "compartment connector" 82.

[0081] In this embodiment, the end connector 152 and the compartment connector 82 are oriented to connect in a vertical direction. Specifically, the end connector 152 faces downward, while the compartment connector 82 faces upward. Additionally, the end connector 152 and the electrical connector 82 of the battery compartment 80 are blind mating connectors such that when the battery assembly 100 is inserted into the battery compartment 80 without any additional tools, the end connector 152 automatically connects (docks) to the electrical connector 82 in the battery compartment 80. The compartment connector 82 is electrically coupled to electrical and / or electronic components of the robot 25 such that when the battery assembly 100 is received in the battery compartment 80 and connected to the compartment connector 82, the battery assembly 100 is electrically coupled to the robot 25 to provide power to one or more electrical components of the robot 25, such as a drive assembly, a lift assembly 33, a container holding device 37, a wireless communication component, a robot control system, etc.

[0082] Figure 9 Shown is a view of the robot 25 from Figure 6 wherein an area 48 is marked with a dashed line. The battery compartment can be located anywhere within the area 48. For example, the battery compartment can be entirely within the outer body 27 of the robot 25, or the battery compartment can extend through the top side 28 of the outer body 27 of the robot 25, or the battery compartment 80 can be entirely above the outer body 27 of the robot 25.

[0083] The battery compartment 80 is also exposed so that the battery receiving space can be accessed from the outside at a position above the outer body 27 of the robot 25. The top side 28 of the outer body 27 of the robot 25 includes an opening 47. When the battery compartment 80 is completely located within the outer body 27 of the robot 25, the opening 47 can communicate with the top opening of the battery compartment 80. This enables the battery assembly 100 to be directly inserted into the battery compartment 80 via the opening 47 from a position above the top side 28 of the outer body 27 of the robot 25, and to be directly removed from the battery compartment 80 via the opening 47 to a position above the top side 28 of the outer body 27 of the robot 25. When the battery compartment 80 extends through the top side 28 of the outer body 27 of the robot 25, the battery compartment 80 can extend through the opening 47. When the battery compartment 80 is completely located above the outer body 27 of the robot 25, the battery compartment 80 can be mounted on the top side 28 of the outer body 27 of the robot 25 and the opening 47 may not be required.

[0084] Figure 9 The illustrated outer body 27 of the robot 25 is defined by a top panel and side panels. Figure 10 Another embodiment of the outer body 27 of the robot 25 is shown, which includes corner blocks 60 connected by horizontal connecting elements 62a and vertical connecting elements 62b (such as rods) to form an open frame structure. This open frame structure can be used to house and / or support components of the robot 25, such as a drive assembly and a lifting assembly 33. Due to the open frame structure of the outer body, the top side of the outer body 27 thus has an opening 47, which is formed by the corner blocks 60 and the horizontal connecting elements 62a at the top side of the robot 25. Similar to Figure 9 the robot 25 shown, the battery compartment 80 can be completely located within the outer body 27 of the robot 25 and communicate with the opening 47, or the battery compartment 80 can extend through the opening 47 of the outer body 27 of the robot 25, or can be completely located above the outer body 27 of the robot 25.

[0085] Figure 11 is a perspective view of a separate battery assembly 100. The battery assembly 100 includes a battery pack 110 and a service box 130, and the service box 130 is detachably attached to the side of the battery pack 110 to form a single rigid assembly that can be moved as a single unit.

[0086] The overall shape of the battery assembly 100 is substantially a cubic shape. The battery assembly 100 includes four positioning members 102 extending along four vertical edges between the corners of the battery assembly 100. The positioning member 102 includes a tapered surface 103 such that when the battery assembly 100 is inserted into the battery compartment 80, the tapered surface 103 of the positioning member 102 can engage with the side wall 84 of the battery compartment 80, thereby self-positioning the battery assembly 100 in the battery compartment 80.

[0087] Figure 12 A separate battery pack 110 is shown. The battery pack 110 includes an outer battery pack housing 112 that houses battery cells and a battery management system (BMS) for managing the battery cells. The battery pack 110 is preferably a rechargeable battery pack. The BMS includes one or more controllers configured to monitor the state of the battery pack 110. For example, the BMS can monitor at least one of the following: the voltage, temperature, current, battery health, and state of balance of the battery cells.

[0088] The battery pack 110 further includes a power connector 120 and a signal connector 122 disposed on the connection surface 114 of the battery pack housing 112. Hereafter, the power connector 120 and the signal connector 122 of the battery pack 110 will be referred to as the "base power connector" 120 and the "base signal connector" 122, respectively. The connection surface 114 of the battery pack housing 112 of the battery pack 110 refers to the surface facing the service box 130 when the battery pack 110 is attached to the service box 133. In this embodiment, when the battery assembly 100 is oriented to be inserted into the battery compartment 80 in the horizontal direction and the base power connector 120 and the base signal connector 122 are oriented to be connected to the corresponding electrical connectors in the horizontal direction, the connection surface 114 faces the horizontal direction. The base power connector 120 can be any suitable electrical connector for connecting to a corresponding power connector of an external device to allow power transfer between the battery pack 110 and the external device. The base signal connector 122 is electrically coupled to the BMS and can be any suitable electrical connector for connecting to a corresponding signal connector of an external device to allow signal or data transfer between the BMS and the external device. When the battery pack 110 appears alone (i.e., not attached to the service box 130), the base power connector 120 and the base signal connector 122 are externally exposed on the connection surface 114 of the battery pack housing 112.

[0089] Figure 13A separate service box 130 is shown, with the side facing the battery pack 110 shown during the assembly of the battery assembly 100. The service box 130 includes an outer service box housing 112 having a connection surface 134 that faces the connection surface 114 of the battery pack 110 when the service box 130 is attached to the battery pack 110. The service box housing is made of a substantially rigid material (such as a metal plate) to form a rigid structure. The service box 130 further includes a power connector 140 and a signal connector 142 disposed on the connection surface 134. Hereafter, the power connector 140 and the signal connector 142 on the connection surface 134 of the service box 130 will be referred to as the "intermediate power connector" 140 and the "intermediate signal connector" 142, respectively. When the service box 130 appears alone (i.e., not attached to the battery pack 110), the intermediate power connector 140 and the intermediate signal connector 142 are externally exposed on the connection surface 134 of the service box housing 132.

[0090] The intermediate power connector 140 is configured to connect (mate) to the base power connector 120, and the intermediate signal connector 142 is configured to connect (mate) to the base signal connector 122. Since the base connectors 120, 122 are oriented to connect in the horizontal direction, the intermediate connectors 140, 142 are also oriented to connect in the horizontal direction. In the illustrated embodiment, for safety reasons (such as to reduce the risk of short circuit of the battery pack 110), the intermediate connectors 140, 142 are male connectors, while the base connectors 120, 122 are female connectors, but it can also be the other way around. The base power connector 120 and the intermediate power connector 140, as well as the base signal connector 122 and the intermediate signal connector 142, are also blind-mate connectors, that is, by pushing the connection surface 114 of the battery pack 110 against the connection surface 134 of the service box 130, the connectors can be mated without any additional tools.

[0091] Refer to Figures 11 - 13, the battery pack 110 and the service box 130 are attached to each other via screws 104, and the screws 104 are received in the screw holes 118 of the battery pack housing 112 and the screw holes 138 of the service box housing 132. The screw holes 118 of the battery pack housing 112 and the screw holes 138 in the service box housing 132 are arranged such that they are aligned when the base connectors 120, 122 are connected to the intermediate connectors 140, 142 for receiving the screws 104. To facilitate the attachment of the service box 130 to the battery pack 110, the service box housing 132 includes a flange 135, and the screw holes 138 of the service box 130 are defined to pass through the flange 135. Alternatively, the battery pack housing 112 may include a flange, or both the service box housing 132 and the battery pack housing 132 may include flanges, and the screw holes 118, 138 are defined to pass through the flanges. The battery pack 110 and the service box 130 are not limited to being attached together by screws. Other types of fasteners, such as bolts and nuts, may also be used, or any other suitable type of detachable attachment means, such as interlocking portions that snap together on the battery pack housing 112 and the service box housing 132, may be used.

[0092] Once the battery pack housing 112 is attached to the service box housing 132, the battery pack 110 and the service box 130 cannot move relative to each other. Therefore, the base connectors 120, 122 and the intermediate connectors 140, 142 cannot be disconnected from each other until the battery pack housing 112 and the service box housing 132 are separated.

[0093] Continuing to refer to Figures 11 - 13 , the battery pack housing 112 includes two guide pins 116 extending from the connection surface 112 in a direction parallel to the connection direction of the base connectors 120, 122, while the service box housing 132 includes two corresponding guide holes 136 for receiving the two guide pins 116 when the connection surfaces 114, 134 move towards each other. The purpose of the guide pins 116 and the guide holes 136 is to facilitate the alignment of the base connectors 120, 122 with the intermediate connectors 140, 142 and the alignment of the screw holes 118, 138 of the battery pack housing 112 and the service box housing 132 when the battery pack 110 and the service box 130 are coupled together. The guide pins 116 and the guide holes 136 are arranged such that when the guide pins 116 are aligned with the guide holes 136, the base connectors 120, 122 are aligned with the intermediate connectors 140, 142 for connection, and the screw holes 118 of the battery pack housing 112 are aligned with the screw holes 138 of the service box housing 132. Therefore, moving the battery pack 110 and the service box 130 towards each other such that the guide pins 116 are received in the guide holes 136 will cause the base connectors 120, 122 to be connected to the intermediate connectors 140, 142 and cause the battery pack housing 112 and the service box housing 132 to be aligned for attachment.

[0094] Alternatively, the service box 130 may include a guide pin 116, and the battery pack 110 may include a guide hole 136. Additionally, the guide pin 116 may be any form of protrusion, and the guide hole 136 may be any form of hole or groove for receiving the protrusion. Generally, each of the battery pack 110 and the service box 130 includes one or more guiding features that cooperate to align the battery pack 110 and the service box 130, thereby aligning the base connectors 120, 122 with the intermediate connectors 140, 142 for connection, and aligning the battery pack housing 112 and the service box housing 132 for attachment.

[0095] Figure 14 The side of the service box 130 opposite to the Figure 13 shown side is illustrated, with the positioning member 102 removed to enable viewing of other components. The end connector 152 is part of an end connector assembly 150 mounted on the service box housing 132 such that the end connector 152 is exposed when the battery pack 110 and the service box 130 are attached together. As described above, the end connector 152 is arranged to face downward for connection to the upward-facing connector 82 of the battery compartment 80 when the battery assembly 100 is inserted into the battery compartment 80.

[0096] Figure 15A and Figure 15B An individual end connector assembly 150 is illustrated. Figure 15A The bottom (outward-facing) side of the end connector assembly 150 is illustrated, while Figure 15BShows the top (inward) side of the end connector assembly 150. In the illustrated embodiment, the end connector 152 is a modular connector that includes a power connector module 152a and a signal connector module 152b mounted together within a framework 153 so that the end connector 152 can be moved as a single unit. Although the power connector module 152a and the signal connector module 152b can each be considered a power connector and a signal connector, for the purpose of illustrating this embodiment, they are still collectively referred to as a single end connector 152. The end connector assembly 150 includes a support plate 154 on which the end connector 152 is mounted. The support plate 154 includes through-holes in which the end connector 152 is located such that the bottom side of the end connector 152 is exposed on the bottom side of the support plate 154 and the top side of the end connector 152 is exposed on the top side of the support plate 154. The end connector assembly 150 further includes two alignment pins 156 mounted on the support plate 154, each alignment pin 156 extending through a respective hole in the support plate 154. Each alignment pin 156 includes a bottom (outward) portion 156a that extends downward (i.e., in a direction parallel to the connection direction of the end connector 152) from the bottom side of the support plate 154 such that the alignment pin 156 protrudes beyond the bottom side of the end connector 152. Each alignment pin 156 further includes a top (inward) portion 156b that extends upward from the top side of the support plate 154. The top portion 156b and the bottom portion 156a of the alignment pin 156 have a generally cylindrical shape. The bottom portion 156a also tapers radially inwardly to form a conical or frustoconical distal end. The end connector 152 and the alignment pins 156 are both rigidly connected to the support plate 154 such that the end connector assembly 150 moves as a single unit.

[0097] Figure 16Shows the top side of an exemplary compartment connector 82, where the top side can be connected (docked) to the bottom side of the end connector 152. The compartment connector 82 also includes modular electrical connectors of a power connector module 82a and a signal connector module 82b. In the illustrated embodiment, for safety reasons (e.g., to reduce the risk of short - circuiting the battery pack 100 when the service box 130 is attached), the power connector module 82a and the signal connector module 82b of the compartment connector 82 are male connectors, while the power connector module 152a and the signal connector module 152b of the end connector 152 are female connectors, but it can also be the other way around. The compartment connector 82 further includes alignment holes 83 for receiving alignment pins 156 of the end - connector assembly 150 when the battery assembly 100 is inserted into the battery compartment 80. The alignment holes 83 are positioned relative to the power connector module 82a and the signal connector module 82b of the compartment connector 82 such that when the alignment pins 156 are aligned with the alignment holes 83, the power connector module 82a and the signal connector module 82b of the compartment connector 82 are aligned with the end connector 152 for connection. The tapered distal end of the alignment pin 156 helps to self - position the alignment pin 156 in the alignment grooves 83 as the end connector 152 approaches the compartment connector 82.

[0098] Figure 17 Shows the interior of the service - box housing 132 when empty. The portion of the service - box housing 132 where the end - connector assembly 150 is mounted includes a central opening 144 for receiving the end connector 152, and two circular openings 146 on either side of the central opening 144 for receiving the top portions 156b of the alignment pins 156. Figure 18A Shows the same view as Figure 17 except with the end - connector assembly 150 mounted on the service - box housing 132. The support plate 154 is located outside the service - box housing 132, and the top side of the end connector 152 and the top portions 156b of the alignment pins 156 are respectively received in the central opening 144 and the circular openings 146. Nuts 160 are threaded onto the ends of the top portions 156b of each alignment pin 156, and washers 162 are located between the nuts 160 and the inner surface of the service - box housing 132. The diameter of each washer 162 is greater than the diameter of the circular opening 146 to prevent the support plate 154 from detaching from the service - box housing 132, and the nuts 160 are tightened to prevent the end - connector assembly from moving in the vertical direction.

[0099] Figure 18B Shows the same view as Figure 18AThe same view, except that the nut 160 and washer 162 are removed. As can be seen therefrom, the diameter of the top portion 156b of the alignment pin 156 is smaller than the diameter of the circular opening 146, which enables the support plate 154 to move in any horizontal direction (i.e., any direction perpendicular to the connection direction of the end connector 152) by a distance determined by the diameter of the circular opening 146. The end connector 152 is thus configured as a "floating" connector, which helps the end connector 152 to successfully connect to the compartment connector 82 - even if there is a large misalignment in the horizontal direction between the two connectors. Such misalignment may result from large manufacturing tolerances in the size and relative position of the components of the battery assembly 100 and / or the battery compartment 80 and / or the robot 25.

[0100] Although the above-described end connector 152 and compartment connector 82 are modular electrical connectors that combine a power connector module and a signal connector module in a single unit, the service box 130 and the battery compartment 82 are not limited to including the modular end connector 152. Instead, the service box 130 may include an end power connector and a separate end signal connector, and the battery compartment 80 may include a compartment power connector and a separate compartment signal connector. The separate end power connector and end signal connector may still be part of the same end connector assembly (i.e., mounted on the same support plate), or alternatively, they may be part of different end connector assemblies that are separately configured to float in the same manner as the above-described end connector 152. Additionally, the circular opening 146 in the service box housing 132 may have a different shape to limit the direction in which the end connector 152 can move relative to the service box housing. For example, the circular opening 146 may be a rectangular or pill-shaped opening, and its size is designed to limit the movement of the end connector 152 along a specific axis. In an alternative embodiment, the compartment connector 82 may be configured to move relative to the battery compartment 80 in a direction perpendicular to the connection direction of the compartment connector 82 (rather than the end connector 152) using an arrangement similar to the above-described arrangement for the end connector 152.

[0101] Figure 19Shows a cable assembly 170 housed within a service box housing 132. The cable assembly 170 includes a cable that electrically couples intermediate connectors 140, 142 to an end connector 152. Specifically, the cable assembly 170 includes a positive cable 172 and a negative cable 174. The positive cable 172 connects the positive terminal of the intermediate power connector 140 to the positive terminal of the power connector module 152a of the end connector 152. The negative cable 174 connects the negative terminal of the intermediate power connector 140 to the negative terminal of the power connector module 152a of the end connector 152. The service box 130 further includes a fuse 175 that is electrically coupled between the intermediate power connector 140 and the end connector 152 to provide overcurrent protection when the service box 130 is electrically coupled to the battery pack 110. In the illustrated embodiment, the fuse 175 is connected between two portions of the positive cable 172 via a bus bar 171. The cable assembly 170 further includes a signal cable 176 that connects the intermediate signal connector 142 to the signal connector module 152b of the end connector 152. Thus, when the service box 130 is attached and electrically coupled to the battery pack 110, power and signals can be transmitted between the battery pack 110 and the robot 25 via the electrical components of the service box 130, including the intermediate connectors 140, 142, the cable assembly 170, and the end connector 152.

[0102] The battery assembly 100 and the battery compartment 80 of the robot 25 form part of a battery replacement system in which the battery assembly 100 within the battery compartment 80 of the robot 25 can be replaced with another battery assembly 100, e.g., a power-depleted battery assembly 100 can be replaced with a fully-charged battery assembly 100. The battery replacement can be performed manually, but for safety and efficiency reasons, the battery replacement is preferably performed automatically using a robotic arm.

[0103] The robotic arm used in the battery replacement system can include any suitable end effector for engaging the battery assembly 100 to allow the robotic arm to move the battery assembly 100 into and out of the battery compartment 80. For example, the battery assembly 100 can include a handle mounted on top of the battery assembly, and the end effector can include a clamping assembly for releasably gripping the handle. Other exemplary engagement mechanisms that can be used in the present system are described in UK Patent Applications Nos. GB2211853.3, GB2207553.5, and GB2216843.9, each of which is incorporated herein by reference.

[0104] To minimize the downtime of the robot 25 during a battery replacement operation, the robotic arm can be located on the track structure 13 of the storage structure 1, above the track structure 13, or adjacent to the track structure 13 so that the robotic arm can access the battery compartment 80 of the robot 25 when the robot 25 is stationed on the track structure 13. The robotic arm can have any necessary degrees of freedom to enable the end effector to move the battery assembly 100 between the battery compartment 80 of the robot 25 and a lowering position outside the battery compartment 80. During battery replacement, the battery compartment of the robot 25 can be at a predetermined position relative to the robotic arm 50 so that the robotic arm 50 can be configured to perform a series of predetermined movements to effect the battery replacement.

[0105] Figure 20 An exemplary robotic arm in the form of a gantry-type mechanism 50A is shown, where the end effector 51 is mounted on a gantry that extends over a row of designated grid cells 14a of the track structure 13. The shown gantry-type mechanism 50A is configured to move the end effector 51 in a vertical direction and in a first horizontal direction parallel to the row of designated grid cells 14a of the track structure 13 such that the end effector 51 can reach the robot 25 on any one of the designated grid cells 14a in the row and lower and raise the end effector to move the battery assembly 100 into and out of the battery compartment 80 of the robot 25. The gantry-type mechanism 50A can be further configured to move the end effector 51 in a second horizontal direction perpendicular to the first horizontal direction to allow the end effector to move over multiple rows of designated grid cells 14a.

[0106] Figure 21 An exemplary robotic arm in the form of an articulated mechanism 50B is shown, which is located adjacent to the track structure 13 such that the end effector 51 can access the battery compartment 80 of the robot 25 on a designated grid cell 14a at the edge of the track structure 13 or on one of a plurality of designated grid cells 14a. However, the articulated mechanism 50B can also be located on the track structure 13 (e.g., on grid cell 14) to allow the end effector to reach the compartment of the robot 25 on a designated grid cell 14a near the middle of the track structure 13 or on one of a plurality of designated grid cells 14a.

[0107] The battery replacement system further includes one or more battery stations 70 for storing battery assemblies 100 that have been removed from the battery compartment 80 of the robot 25 and for storing battery assemblies 100 to be inserted into the empty battery compartment 80 of the robot 25. Figure 22An exemplary battery station 70 including a plurality of slots 72 is shown. Each slot 72 is open toward the top surface 71 of the battery station 70 such that each slot 72 can receive a battery assembly 100 in a downward direction. The battery station 70 preferably includes a charging system configured to charge the battery assembly 100 when the battery assembly is received in the slot 72. For example, each slot 72 may include an electrical connector similar to or the same as the compartment connector 82 for connection to the end connector 152 to electrically couple the battery assembly 100 to the charging system, thereby allowing the charging system to charge the battery assembly 100. The charging system may include a power source, a charging controller, and suitable circuitry configured to charge the battery assembly 100 using power from the power source.

[0108] Each battery station 70 is within reach of one or more robotic arms 50 so that each robotic arm 50 can move the battery assembly 100 between the battery compartment 80 of the robot 25 and the slots of the battery station 70. For example, the battery station 70 may be located Figure 20 and Figure 21 in the area 52 marked in the figure, which area 52 is adjacent to or near the track structure 13. The robotic arm 50 may be mounted on the battery station 70 to minimize the overall footprint of the robotic arm 50 and the battery station 70.

[0109] Figure 23 is a block diagram of an exemplary control system of a storage and retrieval system including a battery replacement system. The positions of the robots 25 on the track structure 13 and the routes between their positions on the track structure 13 are controlled by a central control system 180 including one or more controllers that wirelessly communicate with each robot 25 on the track structure 13 using a wireless transmitter and receiver and suitable wireless communication technologies (such as 4G, 5G, Wi-Fi, etc.). One or more controllers of the central control system 180 receive data related to the products entering the storage and retrieval system and related to the products that a customer has ordered, and use this data to calculate the routes of the robots 25 between the target grid cells 14 to pick up and drop off a specific storage container 50 at a specific location. One or more controllers of the central control system 180 command the robots 25 to move to the target grid cell 14 along the calculated route and pick up or drop off the storage container 50 at the target grid cell 14.

[0110] As described above, the robot 25 includes a robot controller 182 that is configured to control the functions of the robot 25, such as operating the lifting assembly to move the robot 25 in a specific direction and by a specific distance, and operating the lifting assembly 102 to lower and raise the holding frame 110. As described above, the robot controller 182 wirelessly communicates with the central control system 180 via a wireless transmitter and receiver mounted on the robot 25. The robot controller 182 is configured to receive commands from the central control system 180 (such as moving to a specific grid cell 14 along a specific route and picking up or dropping off a storage container 50), and send status updates to the central control system 180 (such as confirming the position of the robot 25 on the track structure 13 and the status of the lifting assembly 102).

[0111] When the battery assembly 100 is within the battery compartment and connected to the compartment connector 82, the robot controller 182 can communicate with the BMS 184 of the battery pack 110 via the signal connectors 122, 142, and the cable assembly 170 of the service box 130. For example, the BMS 184 can transfer the power level of the battery pack 110 to the robot controller 182 so that the robot controller 182 can determine when the robot 25 needs to replace the battery.

[0112] The robotic arm 50 includes an arm controller 186 that is configured to control the movement of the robotic arm 50 and the end effector 51. The charging system of the battery station 70 includes a charging controller 188 that is configured to monitor and control various aspects of the charging system, such as monitoring the occupancy of the slots 72 and the power levels of each battery assembly 100 in the occupied slots 72. The charging controller 188 communicates with the arm controller 186 such that the charging controller 188 can command the robotic arm 50 to place the depleted battery assembly 100 removed from the robot 25 into a specific empty slot 72, and pick up a fully charged battery assembly 100 from a specific occupied slot 72 for insertion into the robot 25.

[0113] The above control system is merely an embodiment of how to arrange the control system of the storage and retrieval system, and other arrangements are also feasible, such as combining multiple controllers, adding additional controllers, and adding or removing communication between controllers.

[0114] The robot 25 can operate on the track structure 13 of the storage structure 1 until the power level of the battery assembly 100 has been depleted beyond a threshold power level. Once this occurs, the robot 25 can convey this situation to the central control system 180, and the central control system 180 then commands the robot 25 to move to the designated grid cell 14a where the robotic arm 50 can perform battery replacement. Once the robot 25 has reached the designated grid cell 14a, the robot controller conveys this situation to the central control system 180, and the central control system 180 then commands the robotic arm 50 to perform battery replacement according to the commands of the charging controller 188 as described above.

[0115] The robotic arm 50 removes the power-depleted battery assembly 100 from the battery compartment 80 of the robot 25 and places it in the empty slot 72 at the battery station 70 for charging. Subsequently, the robotic arm 50 retrieves the fully charged (fully charged or with a power level at least higher than that of the power-depleted battery assembly 100) battery assembly 100 and inserts it into the battery compartment 80 of the robot 25 so that the robot 25 can continue to operate on the track structure 13.

[0116] It should be understood that whenever the battery assembly 100 is moved into or out of the battery compartment 80 or the battery station slot 72, the end connector 152 will connect to or disconnect from the external connector and thus experience wear. In the above storage and retrieval system, the battery assembly 100 can be replaced multiple times a day. Electrical connectors are typically specified to be able to withstand only a certain number of plug and unplug cycles (connection and disconnection), and it is likely that the end connector 152 will reach its service life before the battery pack 110 stops being used due to degradation of its battery cells.

[0117] The number of plug and unplug cycles experienced by the end connector 152 can be tracked, for example, by the central control system by recording each battery replacement of each specific battery assembly 100 in a database. Alternatively or additionally, referring back Figure 19, the cable assembly 170 may further include a first cable 178 and a second cable 179. The first cable 178 is electrically coupled between the signal connector module 152b and the positive terminal of the power connector module 152a. The second cable 179 is electrically coupled between the signal connector module 152b and the negative terminal of the power connector module 152b, such that the BMS or the robot controller 182 can measure the voltage between the positive terminal and the negative terminal of the power connector module 152a of the end connector 152 through the signal connector module 152b. Based on the voltage measurement and the known current, the resistance between the positive terminal and the negative terminal of the power connector module 152a can be determined and monitored. It is known that the resistance of an electrical connector increases with the increase in the number of plugging and unplugging cycles. Therefore, once the monitored resistance increases and exceeds the threshold resistance corresponding to the threshold number of plugging and unplugging cycles, the robot controller 182 can transmit the information that the battery assembly 100 needs maintenance to the central control system.

[0118] Once the end connector 152 has reached its rated number of plugging and unplugging cycles (or other predetermined number of plugging and unplugging cycles), the battery assembly 100 can be maintained by removing the service box housing 132 from the battery pack housing 112 (by unscrewing the screw 104) and separating the service box 130 from the battery pack 110 to disconnect the base connectors 120, 122 from the intermediate connectors 140, 142. Subsequently, the worn end connector 152 can be replaced with a new end connector 152, and then the original service box 130 can be reattached to the original battery pack 110. Alternatively, the original service box 130 can be completely replaced with another service box 130 equipped with a new end connector 152.

[0119] Thus, the service box 130, as a sacrificial interface between the battery pack 100 and the robot 25, minimizes the wear of the base electrical connectors 120, 122 of the battery pack 100 during the use of the battery pack 110. Specifically, the base connectors 120, 122 only experience wear when the service box 130 is coupled to and decoupled from the battery pack 110, rather than every time the battery assembly 100 is connected to and disconnected from the robot 25 or the battery station. In addition, once the service box 130 is decoupled from the battery pack 110, the service box 130 is in a non-powered state. Therefore, replacing the end connector 152 does not require the staff to be trained in battery operation. Thus, by minimizing the need to replace the base connectors 120, 122 of the battery pack 110 itself, the end connector 152 of the battery assembly 100 can be replaced quickly, efficiently, and cost-effectively.

[0120] The above-described arrangement of the service box 130 and the battery pack 110 also has advantages related to the center of gravity of the robot 25. Generally, for stability considerations, it is preferred that the robot 25 have as low a center of gravity as possible, for example, to avoid the robot 25 tipping over during acceleration and deceleration. The battery pack 110 is typically one of the heaviest components in the robot 25. Therefore, the vertical position of the battery assembly 110 within the robot 25 has a significant impact on the position of the center of gravity of the robot 25. By arranging and orienting the base connectors 120, 122, the intermediate connectors 140, 142, and the end connector 152 such that while providing a downward-facing end connector 152 for connection to the compartment connector 82, the service box 130 can still be attached to the side of the battery pack 110, the vertical position of the battery pack 110 within the robot 25 is substantially the same as the vertical position when the battery pack 110 is not provided with the service box 130. Thus, compared to an arrangement where, for example, the service box 130 is attached to the bottom of the battery pack 110, the above-described arrangement has a minimal impact on the center of gravity of the robot 25. More generally, by providing the service box 130 for the battery pack 110, the end connector 152 of the battery assembly 100 can be positioned and oriented in any desired direction without regard to the position and orientation of the base connectors 120, 122 of the battery pack 110, which can result in, for example, the above-described advantages related to the center of gravity.

[0121] The present invention is not limited to the above exact forms, and various modifications and variations are also obvious to those skilled in the art.

[0122] For example, the battery assembly 100 is not limited to being used with the robot 25 of the above-described storage and retrieval system. The battery assembly 100 can be used in any battery replacement system having a battery-powered device that includes a battery compartment for removably receiving and electrically coupling to the battery assembly 100. Additionally, the battery assembly 100 is not limited to being used in a specific orientation; the service box 130 is not limited to being attached to any particular side of the battery pack 110 (as long as the base connectors 120, 122 and the intermediate connectors 140, 142 are arranged accordingly); and the end connector is not limited to being oriented to connect to an external device in any particular direction. In other words, the arrangement between the battery pack 110 and the service box 130 and the arrangement of their respective electrical connectors can be modified from the above-described embodiments to match the specific battery-powered device of the battery replacement system. For example, the battery compartment 80 can be configured to receive the battery assembly 100 in a horizontal direction, and the compartment connector 82 can also be configured to connect in a horizontal direction, in which case the end connector 152 can also be arranged and configured to connect in a horizontal direction rather than a vertical direction.

[0123] In addition, the battery pack 110 and the service box 130 do not need to be provided with both a power connector and a signal connector simultaneously. Only one connector or one type of connector (such as only a power connector) can be provided on each of the battery pack 110 and the service box 130, or, more than two connectors or more than two types of connectors can be provided on each of the battery pack 110 and the service box 130 as needed.

[0124] In addition to the end connector 152 being a floating connector, the base connectors 120, 122 and / or the intermediate connectors 140, 142 can also be configured as floating connectors in a similar manner (i.e., they can be configured to move a predetermined distance relative to the battery pack housing 112 or the service box housing 132 in a direction perpendicular to their connection direction) to account for manufacturing tolerances when constructing the battery pack 110 and the service box 130.

Claims

1. A battery assembly, the battery assembly comprising: a battery pack, the battery pack including an outer battery pack housing and a basic electrical connector; and a service box, the service box including an outer service box housing, an intermediate electrical connector, and an end electrical connector, wherein the intermediate electrical connector is electrically coupled to the end electrical connector, and the intermediate electrical connector and the basic electrical connector are configured to be reversibly connected to each other; wherein the battery pack housing is detachably attached to the service box housing to form a single unit, in which the basic electrical connector is connected to the intermediate electrical connector, and the end electrical connector is exposed to allow the battery pack to be electrically coupled to an external device via the service box; wherein the end electrical connector is mounted to the service box housing such that the end electrical connector is movable relative to the service box housing in a direction substantially perpendicular to the connection direction of the end electrical connector.

2. The battery assembly according to claim 1, wherein, The basic electrical connector, the intermediate electrical connector, and the end electrical connector are power connectors configured to allow power to be transmitted from the battery pack to an external device and / or from the external device to the battery pack via the service box.

3. The battery assembly according to claim 2, wherein, The service box includes a fuse coupled between the intermediate electrical connector and the end electrical connector.

4. The battery assembly according to any one of the preceding claims, wherein, The connection direction of the end electrical connector is different from the connection direction of the intermediate electrical connector.

5. The battery assembly according to any one of the preceding claims, wherein, The service box housing is detachably attached to the battery pack housing by one or more fasteners.

6. The battery assembly according to any one of the preceding claims, wherein, The battery pack includes guiding features configured to cooperate with corresponding guiding features of the service box such that the basic electrical connector is aligned with the intermediate electrical connector for connection, and such that the battery pack housing is aligned with the service box housing for attachment.

7. The battery assembly according to any one of the preceding claims, wherein, The end electrical connector includes at least one alignment member for cooperating with at least one corresponding alignment feature of an external electrical connector to align the end electrical connector with the external electrical connector, thereby allowing the end electrical connector to be connected to the external electrical connector.

8. The battery assembly according to claim 7, wherein, The at least one alignment member of the end electrical connector includes a protrusion or a groove extending in a direction parallel to the connection direction of the end electrical connector.

9. The battery assembly according to any one of the preceding claims, wherein, The basic electrical connector is mounted on the battery pack housing such that the basic electrical connector is movable relative to the battery pack housing in a direction substantially perpendicular to the connection direction of the basic electrical connector.

10. The battery assembly according to any one of the preceding claims, wherein, The intermediate electrical connector is mounted on the service box housing such that the intermediate electrical connector is movable relative to the service box housing in a direction substantially perpendicular to the connection direction of the intermediate electrical connector.

11. The battery assembly according to any one of the preceding claims, wherein, The service box further includes a cable assembly, the cable assembly including one or more cables configured to electrically couple the intermediate electrical connector to the end electrical connector.

12. The battery assembly according to any one of the preceding claims, wherein, the battery pack includes a plurality of basic electrical connectors; The service box includes a plurality of intermediate electrical connectors and a plurality of end electrical connectors, wherein each intermediate electrical connector is electrically coupled to a respective end electrical connector, and each intermediate electrical connector is configured to reversibly connect to a respective base electrical connector; Wherein, the battery pack housing is detachably attached to the service box to form a single unit, in which each base electrical connector is connected to a respective intermediate electrical connector, and each end electrical connector is exposed to allow the battery pack to be electrically coupled to an external device via the service box.

13. The battery assembly according to claim 12, wherein, At least one of the plurality of base electrical connectors is a power connector, at least one of the plurality of intermediate electrical connectors is a power connector, and at least one of the plurality of end electrical connectors is a power connector to allow power to be transmitted from the battery pack to an external device and / or from an external device to the battery pack via the service box.

14. The battery assembly according to claim 12 or claim 13, wherein, The battery pack further includes a battery management system, and wherein at least one of the plurality of base electrical connectors is a base signal connector electrically coupled to the battery management system, at least one of the plurality of intermediate electrical connectors is a signal connector, and at least one of the plurality of end electrical connectors is a signal connector to allow signals to be transmitted from the battery management system to an external device and / or from an external device to the battery management system via the service box.

15. A battery replacement system, the battery replacement system comprising a battery assembly as defined in any one of the preceding claims and an external device, the external device including a battery compartment configured to removably receive the battery assembly, wherein, The battery compartment includes a compartment electrical connector configured to reversibly connect to the end electrical connector of the battery assembly to electrically couple the battery assembly to the external device.

16. The battery replacement system according to claim 15, further comprising a robotic arm configured to move the battery assembly into and out of the battery compartment.

17. The battery replacement system according to claim 16, further comprising a battery station, the battery station including one or more slots configured to removably receive the battery assembly and a charging system for charging the battery assembly, wherein, Each slot includes an electrical connector configured to reversibly connect to the end connector of the battery assembly to electrically couple the battery assembly to the charging system, and the robotic arm is further configured to move the battery assembly into and out of the slot and to move the battery assembly between the battery compartment of the external device and the slot of the battery station.

18. The battery replacement system according to any one of claims 15 to 17, wherein, The battery compartment is configured to receive the battery assembly in a downward direction, and the service box is detachably attached to the side of the battery pack.

19. The battery replacement system according to any one of claims 15 to 18, wherein, The battery assembly has an external battery assembly housing defined by the battery pack housing, the service box housing, and the battery assembly, and has one or more positioning members mounted on the battery assembly housing, wherein the positioning members are configured to allow the battery assembly to self-position in the battery compartment when the battery assembly is moved into the battery compartment.

20. The battery replacement system according to any one of claims 15 to 19, wherein, The external device is a loading handling device for lifting and moving containers arranged in stacks in a storage structure, the storage structure including a track structure, the track structure including a first set of tracks and a second set of tracks, the first set of tracks extending in a first direction, the second set of tracks extending in a second direction, the second direction being substantially perpendicular to the first direction to form a grid pattern, the grid pattern defining a plurality of grid cells above the stack of containers, the loading handling device including: a drive assembly configured to move the loading handling device on the track structure; a container holding device configured to releasably hold a container from above; and a lifting mechanism configured to raise and lower the container holding device.

21. A storage and retrieval system, the storage and retrieval system including: a storage structure including: a track structure including a first set of tracks and a second set of tracks, the first set of tracks extending in a first direction, the second set of tracks extending in a second direction, the second direction being substantially perpendicular to the first direction to form a grid pattern defining a plurality of grid cells; and a plurality of upright members configured to support the track structure from below to define a storage area below the track structure for storing stacks of a plurality of containers below each grid cell; and wherein the storage and retrieval system further includes a battery replacement system as defined in claim 20.

22. A method for servicing a battery assembly defined in any one of claims 1 to 14, wherein, The service box is a first service box, and the method includes the following steps: (i) removing the housing of the first service box from the battery pack housing; (ii) separating the first service box from the battery pack to disconnect the connection between the base electrical connector and the intermediate electrical connector; (iii) coupling a second service box to the battery pack to connect the base electrical connector to the intermediate electrical connector of the second service box; and (iv) attaching the service box housing of the second service box to the battery pack housing.

23. A method of servicing a battery assembly as defined in any one of claims 1 to 14, the method including the following steps: (i) removing the service box housing from the battery pack housing; (ii) separating the service box from the battery pack to disconnect the connection between the base electrical connector and the intermediate electrical connector; (iii) replacing or repairing at least one component of the service box; (iv) coupling the service box to the battery pack to dock the first base electrical connector to the electrical connector of the first service box; and (v) attaching the service box housing to the battery pack housing.

24. The method according to claim 23, wherein The at least one component in step (iii) includes the end electrical connector.

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