Battery exchange station and method of exchanging rechargeable batteries at battery exchange station

Abstract

The present invention provides a battery exchange station for charging a plurality of batteries, each of the plurality of batteries comprising a battery management system (BMS), the battery exchange station comprising: i) a cabinet comprising a plurality of battery chargers; ii) a plurality of compartments, each compartment configured to receive a battery, the plurality of compartments comprising: a) a plurality of charging compartments, each charging compartment comprising an electrical connector for connecting to a battery received in the charging compartment, each electrical connector electrically coupled to a respective one of the plurality of battery chargers; b) one or more non-charging buffer bins, each non-charging buffer bin comprising coupling means configured to establish communication with a BMS of a battery received in the non-charging buffer bin; and iii) a robotic arm configured to exchange a battery located in the battery powered device with a battery located in one of the plurality of charging bins. A storage and retrieval system includes a storage structure including a track structure, one or more load handling devices configured to move on the track structure, and one or more battery exchange stations positioned next to or on the track structure. A method of exchanging a first battery with a second battery at a battery exchange station is provided.

Description

Technical Field

[0001] The present invention relates to a battery exchange station and to a method of performing battery exchange at a battery exchange station. Background Art

[0002] Some commercial and industrial activities require systems capable of storing and retrieving 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 load handling device configured to move on tracks located on top of the grid storage structure. To access the containers in the grid storage structure, the load handling device is equipped with a container holding device for releasably gripping a container at the top of the stack and a lifting mechanism for raising and lowering the container.

[0003] Each load handling unit is powered by a rechargeable battery. These batteries are typically charged locally by driving the load handling unit to a charging station located at the edge of the grid storage structure. The load handling unit remains stationary at the charging station while the battery is charged. This charging period represents a significant source of downtime for the load handling unit and can last for several hours.

[0004] To alleviate the problem of charging downtime, the load handling unit can be powered by replaceable batteries. When the batteries in the load handling unit become depleted, the depleted batteries are replaced with fully charged batteries, so the charging downtime is reduced to the time it takes to replace the batteries, rather than the time it takes to charge the batteries.

[0005] The present invention aims to provide improvements to battery swap systems. Summary of the Invention

[0006] The invention is defined in the appended claims.

[0007] The present invention provides a battery exchange station for charging a plurality of batteries, each of the plurality of batteries including a battery management system (BMS), the battery exchange station including: i) a cabinet containing a plurality of battery chargers; ii) a plurality of bins, each bin configured to receive a battery, the plurality of bins being grouped as: a) a first grouping of bays, the first grouping comprising a plurality of charging bays, each of the plurality of charging bays comprising an electrical connector for connecting to a battery received in the charging bay, each electrical connector being electrically coupled to a respective one of a plurality of battery chargers; b) a second grouping of bins, the second grouping including one or more non-charging buffer bins, each of the one or more non-charging buffer bins including a coupling means configured to establish communication with a BMS of a battery received in the non-charging buffer bin; and iii) a robotic arm configured to exchange a battery located in the battery-powered device with a battery located in one of the plurality of charging bays.

[0008] A non-charging buffer bin may be referred to as a buffer bin, and the two terms may be used interchangeably. Each buffer bin may not be configured to charge a battery received therein. In other words, each buffer bin is not a charging bin. For example, each buffer bin may not be electrically coupled to a battery charger. For example, each buffer bin may not include an electrical connector for connecting to a corresponding electrical connector of a battery.

[0009] The cabinet can be a single unit. A plurality of bins can be housed in the cabinet. This has the following advantages: the cabinet is easy to manufacture, and both the first grouping and the second grouping of bins can be housed in the same cabinet.

[0010] Each of the plurality of bins may be in the form of a receptacle having an opening in a top surface of the cabinet to allow batteries to be received in the receptacle in a vertical orientation. The cabinet may have a single top surface in which all of the bins have their openings.

[0011] The cabinet may include a first top surface and a second top surface, and the corresponding opening of each of the plurality of charging silos in the first grouping may be in the first top surface, and the corresponding opening of each of the one or more non-charging buffer silos in the second grouping may be in the second top surface. The second top surface of the cabinet may be at a lower vertical level than the first top surface of the cabinet. This may be useful if the buffer silos need to be at a height that is more convenient for human workers to access.

[0012] The ratio of the number of charging buffer bins in the first group to the number of non-charging buffer bins in the second group can be between 2:1 and 10:1. The ratio of the number of charging buffer bins in the first group to the number of non-charging buffer bins in the second group is 4:1. In some examples, the second group consists of a single non-charging buffer bin. In other examples, the second group includes a plurality of non-charging buffer bins. This has the advantage of providing redundancy in the event that one of the non-charging buffer bins becomes inoperative.

[0013] One or more of the plurality of bins may include one or more sensors to detect the presence of a battery in the bin.

[0014] One or more of the plurality of bins may further include a visual indicator of the state of charge of the batteries received within the bin. For example, an LED positioned proximate to the bin may indicate whether the batteries in the bin are fully charged. In some examples, different colored LEDs may be used to indicate different levels of state of charge, e.g., green indicating >80% SOC, yellow indicating 50-80% SOC, and red indicating <50% SOC. In some examples, a visual indicator (e.g., an LED) may indicate whether the batteries in the bin are in an error state (e.g., the BMS has an error code, or the temperature of the battery is outside a predetermined range). In some examples, the battery swap station may send a wireless signal to the mobile device having information about the batteries in the bin, such as the SOC or temperature or an error state.

[0015] The battery exchange station may further include a control system configured to: i) determining a state of charge of a battery received within one of a plurality of non-charging buffer bins; and ii) if the state of charge of the battery is below a predetermined threshold charge level, instructing the robotic arm to move the battery from the non-charging buffer bin to one of the plurality of charging bins.

[0016] The control system may be a central control system for the storage and retrieval system, or a separate control system for the battery swap station. Step ii) may be performed by the local arm controller under the direction of the control system. The control system may include one or more processors and a memory storing instructions that, when executed by the one or more processors, instruct the robotic arm to move the battery.

[0017] The control system can be further configured to: i) determining whether a temperature of a battery in any one of the plurality of bins exceeds a predetermined temperature threshold and / or whether a current of a battery in any one of the plurality of bins exceeds a predetermined current; and ii) activating a switch to disconnect the plurality of battery chargers from the plurality of charging bays if the temperature of the battery exceeds a predetermined temperature threshold and / or the current of the battery exceeds a predetermined current.

[0018] The switch may be a circuit breaker, a fuse, or any other switch capable of cutting off the power supply to the charging bay.

[0019] The present invention provides a storage and retrieval system comprising: A storage structure, the storage structure comprising: a plurality of horizontal members arranged to form a grid pattern defining a plurality of grid cells; a plurality of upright members configured to support the horizontal members from below to define a storage area below the grid cells for storing stacks of storage containers; a track structure positioned on top of the horizontal members, wherein the track structure includes a plurality of tracks arranged to form a grid pattern corresponding to the grid pattern formed by the horizontal members; and One or more load handling devices, each load handling device comprising: a drive assembly configured to move the load handling device on the track structure; a container retaining assembly configured to releasably retain a storage container from above; and a lifting assembly configured to raise and lower the container holding assembly to allow the load handling device to lift and lower the storage container into and out of the storage structure and the passageway via the grid cells; One or more battery exchange stations as defined above, wherein each battery exchange station is located next to or on the track structure.

[0020] The present invention provides a method for replacing a first battery with a second battery, wherein the first battery is located in a battery-powered device and the second battery is located in a charging compartment configured to charge the battery, the method comprising the following steps: (i) removing a first battery from the battery-powered device and placing the first battery in a non-charging buffer compartment; (ii) removing the second battery from the charging compartment and placing it in the battery-powered device; and (iii) taking out the first battery from the non-charging buffer compartment and placing it in the charging compartment.

[0021] The present invention provides a method for replacing a first battery with a second battery, wherein the first battery is located in a battery-powered device and the second battery is located in a charging compartment configured to charge the battery, the method comprising the following steps: (i) removing the second battery from the charging compartment and placing it in the non-charging buffer compartment; (ii) removing the first battery from the battery-powered device and placing it in the charging compartment; and (iii) Removing the second battery from the non-charging buffer compartment and placing it in the battery-powered device.

[0022] In any of the above methods, steps (i)-(iii) may be performed by a robotic arm. All steps (i)-(iii) may be performed by the same robotic arm. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a schematic perspective view of a storage structure and containers arranged in the storage structure.

[0024] Figure 2 yes Figure 1 Schematic plan view of the track structure on top of the storage structure.

[0025] Figure 3 Shown in Figure 1 A load handling device is provided on top of the storage structure's track structure.

[0026] Figure 4 is a schematic perspective view of a load handling device with a container holding device located below the bottom of the load handling device.

[0027] Figure 5 yes Figure 4 Schematic perspective view of a load handling device, wherein the side of the outer body is omitted from the view to illustrate the container receiving space.

[0028] Figure 6 yes Figure 5 Schematic perspective view of a load handling device, wherein a container occupies a container receiving space.

[0029] Figure 7A is a schematic perspective view of a load handling device in which batteries are received in a battery compartment.

[0030] Figure 7B is a schematic cross-sectional view of a battery within a battery compartment.

[0031] Figure 8 is a schematic perspective view of a battery exchange station including a cabinet with side panels omitted from view.

[0032] Figure 9 is a schematic perspective view of a battery exchange station with a track structure adjacent to a storage structure.

[0033] Figure 10 is a top view of a load handling device and a battery swap station, illustrating the steps of a method for replacing a battery.

[0034] Figure 11 is a top view of a load handling device and a battery swap station, illustrating the steps of another method of replacing batteries. DETAILED DESCRIPTION

[0035] Figure 1An exemplary storage structure 1 is shown that can be used in a storage and retrieval system to store storage containers 9. The storage structure 1 includes a frame including upright members 3 and horizontal members 5, 7 supported by the upright members 3. The horizontal members 5 extend parallel to each other and to the x-axis as shown. The horizontal members 7 extend parallel to each other and to the y-axis as shown, and also extend transversely to the horizontal members 5. The upright members 3 extend parallel to each other and to the z-axis as shown, and also 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 example shown, the storage containers 9 are arranged in stacks 11 below the grid cells 14 defined by the grid pattern, with the stack 11 of one storage container 9 per grid cell 14.

[0036] Figure 2 A large-scale plan view of a section of track structure 13 is shown, forming Figure 1 18. The storage structure 1 is a 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. The track structure 13 can be provided by the horizontal members 5, 7 themselves (for example, 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 track structure 13 shown includes x-direction rails 17 and y-direction rails 19, that is, a first set of rails 17 extending in the x-direction and a second set of rails 19 extending in the y-direction transversely to the rails 17 in the first set of rails 17. The rails 17, 19 define a hole 15 in the center of the grid cell 14. The size of the hole 15 is designed to allow a storage container 9 located below the grid cell 14 to be lifted and lowered through the hole 15. The x-direction rails 17 are arranged in pairs, separated by grooves 21, and the y-direction rails 19 are arranged in pairs, separated by grooves 23. Other arrangements of the track structure are also possible.

[0037] Figure 3 A plurality of load handling devices 25 are shown moving on top of the storage structure 1 shown in Figure 18. The load handling devices 25 (hereinafter referred to as "robots") are provided with sets of wheels to engage corresponding x- or y-directional tracks 17, 19 to enable the robots 25 to travel across the track structure 13 and to reach specific grid cells 14. The pairs of tracks 17, 19 shown, separated by grooves 21, 23, allow the robots 25 to occupy adjacent grid cells 14 (or pass each other on adjacent grid cells 14) without colliding with each other.

[0038] like Figure 4As shown, the robot 25 includes an outer body 27 having one or more components mounted therein or thereon that enable the robot 25 to perform its intended functions. These functions may include moving across the storage structure 1 on the track structure 13 and raising or lowering the storage containers 9 (e.g., from or to the stack 11) so that the robot 25 can retrieve or place the storage containers 9 at specific locations defined by the grid pattern.

[0039] The robot 25 shown includes a drive assembly comprising first and second sets of wheels 29, 31 mounted on an outer body 27 of the robot 25 and enabling the robot 25 to move in the x and y directions along the tracks 17 and 19, respectively. In particular, the two wheels 29 are provided at Figure 4 17. The two wheels 31 are provided on the shorter side of the robot 25, and two further wheels 29 are provided on the opposite shorter side of the robot 25. The wheels 29 engage with the track 17 and are rotatably mounted on the outer body 27 of the robot 25 to allow the robot 25 to move along the track 17. Similarly, two wheels 31 are provided on the outer body 27 of the robot 25. Figure 4 , and two further wheels 31 are provided on the opposite longer sides 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.

[0040] To enable the robot 25 to move in the first direction and the second direction on the different wheels 29, 31, 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 load handling device 25 to be selectively moved across the tracks 17, 19 of the storage structure 1 in the first direction or the second direction.

[0041] The wheel positioning mechanism may include one or more linear actuators, rotary 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 move at least one set of wheels 29, 31 away from and into contact with the tracks 17, 19. In some examples, only one set of wheels is configured to be raised and lowered, and the action of lowering one set of wheels may effectively lift the other set of wheels away from the corresponding tracks, while the action of raising one set of wheels may effectively lower the other set of wheels into contact with the corresponding tracks. In other examples, both sets of wheels may be raised and lowered, which advantageously means that the outer body 27 of the robot 25 remains at substantially the same height, and therefore the weight of the outer body 27 and components mounted thereon does not need to be raised and lowered by the wheel positioning mechanism.

[0042] The robot 25 also includes a lifting assembly 33 and a container holding assembly 37 configured to raise and lower the storage container 9. The illustrated lifting assembly 33 includes four tethers 35 connected at their lower ends to the container holding assembly 37. The tethers 35 may be in the form of cables, ropes, belts, or any other form of tether having the necessary physical properties for lifting the storage container 9. The container holding assembly 37 includes a clamping mechanism 39 configured to engage with a feature of the storage container 9 to releasably hold the container 9 from above. In the illustrated example, the clamping mechanism 39 includes legs that can be received in corresponding holes 10 in the rim of the storage container 9 and then moved outward to engage the underside of the rim of the storage container 9. The tethers 35 can be wound upward or downward to raise or lower the container holding assembly 37 as needed. One or more motors and winches or other devices may be provided to enable or control the upward and downward winding of the tethers 35.

[0043] exist Figure 5 and Figure 6 , the side of the outer body 27 of the robot 25 has been omitted from view to allow the interior of the robot 25 to be seen. The outer body 27 of the illustrated robot 25 has an upper portion 41 and a lower portion 43. The upper portion 41 is configured to accommodate or support one or more working components (not shown), such as components of the lifting assembly 33 (e.g., a motor), wireless communication components, one or more processors for controlling the operation of the robot 25, etc. The lower portion 43 is arranged below the upper portion 41. The lower portion 43 is open outward at the bottom and defines a container receiving space 45 for accommodating 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 shows the container receiving space 45 before being occupied by a storage container 9, and Figure 6Container receiving space 45 is shown after being occupied by storage container 9. Container receiving space 45 is sized so that a storage container 9 can fit sufficiently within space 45 to enable robot 25 to move across track structure 13 on top of storage structure 1 without the underside of storage container 9 getting stuck on track structure 13 or another portion of storage structure 1. When robot 25 has reached its intended destination, lift assembly 33 controls tether 35 to lower container holding assembly 37 and the corresponding storage container 9 from space 45 to a desired location. The desired location may be a stack 11 of storage containers 9 or an exit point of storage structure 1 (or an entry point of storage structure 1 if robot 25 has moved to collect storage containers 9 for storage in storage structure 1). Although in the illustrated example, upper portion 41 and lower portion 43 are separated by a physical divider, in other examples, upper portion 41 and lower portion 43 may not be physically separated by a specific component or portion of outer body 27 of robot 25. The top-and-bottom configuration of the robot 25 allows the robot 25 to occupy only a single grid cell 14 on the track structure 13 of the storage system 1 .

[0044] In alternative examples, the container receiving space 49 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, where the weight of the outer body 27 of the robot 25 is balanced by the weight of the container 9 to be lifted. In such an embodiment, the frame 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 disposed at corresponding locations on the protruding frame / arm and configured to be raised and lowered from those locations to raise and lower the storage container 9 into the container receiving space 45 adjacent to the outer body 27.

[0045] Figure 7A Shown with Figure 5 and Figure 6 A similar view of the robot 25, but showing the rechargeable battery 80 received within the battery compartment 70 of the robot 25. The lifting assembly 33 and the container holding assembly 37 have been omitted from the view for clarity.

[0046] The battery 80 provides power to one or more components of the robot 100, such as the lift assembly 33, the container holding assembly 37, and the drive assembly. The battery 80 can have any suitable rechargeable battery chemistry, such as lithium-ion, lithium iron phosphate, nickel metal hydride, nickel cadmium, and the like. The battery 80 includes a housing that houses the cells of the battery 80. To facilitate handling of the battery 80, the housing 204 includes one or more engagement features 84 for engagement by an end effector of the robot arm, allowing the robot arm to move the battery 80 into and out of the battery compartment 70. The engagement features 84 can be simple protruding features, such as a handle that can be gripped by an end effector including a gripping assembly, or can be part of a more complex battery retention mechanism for releasably locking the battery 80 in the battery compartment 70. Examples of such battery retention mechanisms are described in UK patent applications Nos. GB2211853.3, GB2207553.5, and GB2216843.9, each of which is incorporated herein by reference.

[0047] The battery chamber 70 is exposed outwardly at the top of the robot 25 so that the battery 80 can be received in a downward direction from a position above the outer body 27 of the robot 25. In the illustrated example, the battery chamber 70 is located within the outer body 27 of the robot 25 and includes an opening in the top surface of the outer body 27 to allow the battery 80 to be moved into and out of the battery chamber 70. In alternative examples, the battery chamber can be located partially within the outer body 27 of the robot 25 (i.e., the battery chamber extends through the top surface of the outer body 27) or located outside the outer body 27 of the robot 25 (e.g., on top of the top surface of the outer body 27 of the robot 25).

[0048] Figure 7B A schematic cross-sectional view of a battery 80 within a battery compartment 70 is shown. The battery 80 includes one or more electrical connectors 82, and the battery compartment 70 includes one or more corresponding electrical connectors 72 that are electrically coupled (directly or indirectly) to components of the robot 25 to be powered by the battery 80. The electrical connectors 82, 72 are configured to electrically couple to each other when the battery 80 is inserted into the battery compartment 70. The electrical connectors 82, 72 can be any suitable electrical connector for delivering power once connected. The electrical connectors 82, 72 can be blind-mate connectors that physically connect via the action of moving the battery 80 into the battery compartment 70.

[0049] Figure 8A battery exchange station 100 is shown at which the battery 80 can be charged and exchanged with the battery 80 in the robot 25. The battery exchange station 100 includes a charging system for charging the battery 80. The charging system includes one or more charging bays 110 and one or more battery chargers 114 connected to a power source. Each charging bay includes an electrical connector 112 electrically coupled to a corresponding battery charger 114. The electrical connector 112 of each charging bay 110 is configured to connect to the electrical connector 82 of the battery 80 (much like the electrical connector 72 of the battery compartment 70) when the battery 80 is inserted into the charging bay 110. Once the electrical connector 82 of the battery 80 and the electrical connector 112 of the charging bay 110 are connected, the battery charger 114 can deliver current to the battery 80 to charge its battery cells. The battery 80 preferably includes a battery management system (BMS) to prevent hazards such as overcurrent, overvoltage, and overtemperature during charging. Each charging bay 110 may further include a sensor (e.g., a light gate) for detecting when the charging bay 110 is occupied by a battery 80, or the charging system may infer that the charging bay 110 is occupied if current is drawn from its associated battery charger. The sensor for detecting the presence of a battery in the bay may be a load cell for detecting the weight of the battery in the bay.

[0050] The battery exchange station 100 further includes a cabinet 102 that houses at least some of the components of the charging system (e.g., battery charger 114), and charging bays 110 located at the cabinet 102. Each charging bay 110 is in the form of a receptacle having an opening in the top surface of the cabinet 102 to allow the battery 80 to be received in a vertical orientation therein. The cabinet 102 preferably includes a door to allow convenient access to the components of the charging system housed within the cabinet 102.

[0051] The cabinet 102 further includes at least one buffer bin 120. Each buffer bin 120 is also in the form of a receptacle having an opening in the top surface 104 of the cabinet 102 to allow the battery 80 to be received in the receptacle in a vertical orientation. In contrast to the charging bins 110, none of the buffer bins 112 are charging bins 110, and they are not part of the charging system. In particular, none of the buffer bins 112 are electrically coupled to the battery charger 114 and, therefore, cannot charge the battery 80. The buffer bins may also be referred to as non-charging buffer bins. In some examples, when the battery 80 is received in the buffer bin 120, none of the buffer bins 120 has an electrical connector for connecting to the electrical connector 82 of the battery 80.

[0052] Each buffer bin 120 includes a coupling means configured to establish communication with the battery management system (BMS) of the battery received in the buffer bin. For example, the coupling means may be an electrical connector (not electrically coupled to the charging system) configured to connect to the electrical connector 112 of the battery 80 to establish communication with the battery's BMS for monitoring purposes, such as monitoring the temperature of the battery 80.

[0053] In some examples, each buffer bin 120 may include one or more sensors, for example, to sense the presence of a battery 80 in the buffer bin 120. As with the charging bin, each buffer bin 120 may further include a sensor (e.g., a light gate) for detecting when the buffer bin 120 is occupied by a battery 80. The sensor for detecting the presence of a battery in the buffer bin may be a load sensor for detecting the weight of the battery in the bin. Alternatively, a connection to a battery management system may be used to infer the presence or absence of a battery.

[0054] Temperature monitoring of the batteries in the buffer silo is a safety feature. If a battery overheats, for example if the measured temperature exceeds a predetermined threshold, appropriate action can be taken. For example, the battery swap station can raise an error, shut down the power supply, and / or activate fire safety features such as sprinklers. A switch can also be activated to disconnect the battery charger from the charging silo.

[0055] In particular, a system having means for monitoring the temperature in the buffer compartment as well as the charging compartment has the advantage of ensuring that the temperature of the battery is always monitored regardless of where the battery is located in the battery exchange station.

[0056] In some examples, the battery can be provided with two types of temperature sensors: one or more first-type temperature sensors that send temperature data to the BMS; and one or more second-type temperature sensors that are electrically connected to the battery's electrical connector rather than through the BMS. In addition to providing a useful cross-check on the data from the first-type temperature sensors, the second-type temperature sensors are independent of the BMS and will therefore still function in the event of a software malfunction. In some examples, the charger will not charge the battery if the temperature reading from one or more second-type temperature sensors is outside a predetermined acceptable temperature range. The second-type temperature sensor is effectively a hardware failsafe mechanism; if there is a software problem, the second-type temperature sensor will still function and be directly accessible through the battery's electrical connector.

[0057] Another advantage of a buffer bin having a connection to the battery's BMS is that the battery state of charge (SOC) can be determined from the BMS. If a battery is in the buffer bin and the battery's SOC is below a predetermined threshold level, a robotic arm can be instructed to move the battery from the buffer bin to the charging bin. This enables the batteries stored in the buffer bin to be "topped up". Even when fully charged, batteries will gradually discharge over time, so leaving batteries in the buffer bin for extended periods of time will cause the batteries to discharge. Knowing the SOC of the batteries in the buffer bin enables the batteries to be moved to the charging bin for charging when necessary. The batteries in the buffer bin can also be monitored to determine if they are ready to be deployed in a battery-powered device.

[0058] The battery exchange station 100 further includes a robotic arm 130 for moving batteries 80 between the load handling device 25 and the battery exchange station 100. In the example shown, the robotic arm 130 is mounted on the cabinet 102, but may alternatively be mounted adjacent to the cabinet 102. The robotic arm 130 includes an end effector 132 adapted to selectively engage and release the engagement features 84 of the batteries 80 to allow the robotic arm 130 to pick up and place the batteries 80 in different locations. The robotic arm 130 has sufficient degrees of freedom to allow the robotic arm 130 to move the batteries 80 between the battery compartment 70, the charging bay 110, and the buffer bay 120 of the robot 25. The robotic arm 130 is shown in the form of an articulated robot including joints and linkages to provide the desired degrees of freedom (e.g., six degrees of freedom), but the robotic arm 130 may also take other forms, such as a gantry robot that can move the end effector 132 in two or three perpendicular directions (i.e., two or three degrees of freedom).

[0059] During the time the robot 25 is operating on the track structure 13 , energy in the battery 80 will continue to be consumed until the depleted battery 80 needs to be replaced with a replacement battery 80 to allow the robot 100 to continue operating on the track structure 13 .

[0060] Figure 9A battery exchange station 100 is shown positioned proximate to the track structure 13. For example, the battery exchange station 100 may be located on a mezzanine floor at the same height as the track structure 13. The track structure 13 has one or more designated grid cells 14a to which the robot 25 needs to move in order to perform a battery replacement. The designated grid cell 14a is a grid cell 14 positioned adjacent to the battery exchange station 100 that can be accessed by the end effector 132 of the robotic arm 130. Depending on the reach of the robotic arm 130, the battery exchange station 100 may have more than one designated grid cell 14a in its vicinity. Once the robot 25 has moved to the designated grid cell 14a, the battery chamber 70 may be in a predetermined position relative to the robotic arm 130 so that the robotic arm 130 can perform a set of predetermined movements of the end effector to engage and move the battery 80 to perform a battery replacement. Thus, the battery 80, battery compartment 70, and battery exchange station 100 form part of a battery exchange system, wherein the battery 80 in the robot 25 can be exchanged in an automated manner with the battery 80 in the charging bay 110 while the robot 25 remains on the track structure 13. In an alternative example, the battery exchange station 100 can be located on the track structure 13 itself, rather than immediately adjacent to the track structure 13.

[0061] To exchange the depleted battery 80 in the robot 25 with the charged battery 80 in the charging compartment 110 of the battery exchange station 100, the robot arm 130 may perform the following first exemplary method, such as Figure 10 As shown, Figure 10 The robot 25 and battery exchange station 100 are shown from above. The robotic arm 130 has been omitted for clarity.

[0062] In step (A), the robot 25 having a depleted battery 80a in its battery compartment 70 has arrived at a designated grid cell 14a next to the battery exchange station 100. Each charging bay 110 is occupied by a charged or charging battery 80. The buffer bay 120 is unoccupied.

[0063] In step (B), the robotic arm 130 has engaged and removed the depleted battery 80 a from the robot 25 , and has then placed and released the depleted battery 80 a in one of the buffer bins 120 .

[0064] In step (C), the robotic arm 130 has engaged the charged battery 80b and removed it from one of the charging bays 110, and has then placed and released the charged battery 80b in the battery chamber 70 of the robot 25 so that the robot 25 can move away from the designated grid unit 14a and continue normal operation on the storage structure 1 using power from the charged battery 80b.

[0065] In step (D), the robotic arm 130 has engaged the exhausted battery 80 and removed it from the buffer bin 120, and has then placed and released the exhausted battery 80a in an empty charging bin 110 (i.e., the charging bin 120 from which the charged battery 80b was just removed) so that the exhausted battery 80a can begin charging.

[0066] The robot 130 can also perform a second alternative method, such as Figure 11 shown.

[0067] In step (a), the robot 25 with the depleted battery 80a in its battery compartment 70 has arrived at a designated grid cell 14a next to the battery exchange station 100. Each charging bay 110 is occupied by a charged or charging battery 80. The buffer bay 120 is unoccupied.

[0068] In step (B), the robotic arm 130 has engaged and removed the charged battery 80 b from the charging bay 110 , and then has placed and released the charged battery 80 b in one of the buffer bays 120 .

[0069] In step (C), the robotic arm 130 has engaged and removed the depleted battery 80a from the robot 25, and has then placed and released the depleted battery 80a in the vacant charging bay 110 so that the depleted battery 80a can begin charging.

[0070] In step (D), the robotic arm 130 has engaged the charged battery 80b and removed it from the buffer bin 120, and has then placed and released the charged battery 80b in the battery chamber 70 of the robot 25 so that the robot 25 can move away from the designated grid unit 14a and continue normal operation on the storage structure 1 using power from the charged battery 80b.

[0071] It can be seen that in each method, the buffer bin 120 acts as an intermediate / temporary holding area for placing the battery 80 during battery replacement, particularly when the battery 80 is moved from the robot 25 to the charging bin 110, or when the battery 80 is moved from the charging bin 110 to the robot 25, depending on which of the two above methods is being performed.

[0072] In either method, the state of charge of the depleted battery 80a need not be 0% or nearly 0% at the time of replacement, but may be just equal to or below a predetermined threshold, such as 10% or lower. Similarly, the state of charge of the charged battery 80b need not be 100% at the time of replacement, but may be just equal to or above a predetermined threshold, such as 80% or higher, or at least higher than the state of charge of the depleted battery 80a. Furthermore, the charged battery 80b need not have stopped charging at the time of replacement and may instead still be charging.

[0073] The first and second methods are similar in effect, but in the first method, the time that the charged battery 80 b spends in the charging bin 110 can be maximized, and thus the charged battery 80 b can have a higher state of charge when placed in the robot 25, which allows the robot 25 to operate for a longer time before needing to return to the battery exchange station 100. On the other hand, in the second method, the time that the robot 25 needs to spend at the battery exchange station 100 can be minimized, especially if the charged battery 80 b is moved to the buffer bin 120 before the robot 25 arrives at the battery exchange station 100 (i.e., just before the robot 25 arrives at the battery exchange station).

[0074] As can be seen, to perform the above method, the minimum number of charging bins 110 and buffer bins 120 required by the battery exchange station 100 is one of each. However, providing a plurality of charging bins 110 provides redundancy and increases the likelihood that a battery 80 with a high state of charge is present in one of the charging bins 110 for placement in the robot 25. Providing a plurality of buffer bins 120 also provides redundancy in the event that there is a problem with one of the buffer bins 120 or a battery 80 in one of the buffer bins 120.

[0075] As can be seen, by using the buffer bin 120 as an intermediate / temporary holding area during each battery swap operation, the charging bin 110 only needs to be vacant at the point where the battery swap operation is occurring. Without the buffer bin 120, the battery swap station 100 would need to keep at least one charging bin 110 unoccupied at all times in anticipation of future battery swap operations in order to provide a location for the depleted battery 80a to be moved into before the charged battery 80b can be moved into the robot 25. Thus, the battery swap station 100 allows all charging bins 110 to be occupied with batteries 80 most of the time, maximizing the utilization of each charging bin 110. This is particularly advantageous because each charging bin 110 is relatively expensive, and therefore keeping a charging bin 110 empty at all times would be an inefficient use of capital. An alternative solution to providing a buffer bin 120 could be to provide the battery swap station 100 with two robotic arms 140, each configured to substantially simultaneously swap the depleted battery 80a in the robot 25 with the charged battery in the charging bin 110. However, the capital cost of the robotic arm 130 is high, so a battery swap station 100 that only requires the use of a single robotic arm 140 and the relatively inexpensive buffer bin 120 provides an economical way to maximize the use of the charging bin 110.

[0076] The battery exchange station 100 can also be configured to allow a human worker to manually activate the robotic arm 130 to move batteries 80 from the buffer bin 120 to the charging bin 110 and / or vice versa. In particular, the battery exchange station 100 can include a computer terminal 140 that is communicatively coupled to the robotic arm 130 and configured to send commands to the robotic arm 130 to instruct it to move batteries 80 from a specific buffer bin 120 to the charging bin 130 and / or vice versa. If a worker wishes to place a battery 80 in a charging bin 110, the worker can first place the battery 80 in the buffer bin 120 and then instruct the robotic arm 130 to move the battery 80 from the buffer bin 120 to the charging bin 110 via the computer terminal 140. If the worker wishes to retrieve the battery 80 from the charging bin 110, the worker can instruct the robotic arm 130 to move the battery 80 from the specific charging bin 110 to the buffer bin 110 via the computer terminal 140, and the worker can retrieve the battery 80 from the buffer bin 110. This may be useful, for example, if the charging bay 110 is too high above the floor to allow a human worker to comfortably access the charging bay 110. In this case, the buffer bay 120 may be located lower than the charging bay 110, at a height that is more comfortably accessed by a human worker, such as Figure 9 shown.

[0077] The storage and retrieval system may further include a central control system including one or more controllers configured to command the robots 25 to move to a specific grid cell 14 on the track structure 13 and to command the robotic arms 130 to perform the above-described method for replacing the batteries 80. Each robot 25 may include a local robot controller configured to receive and execute commands from the central control system, such as by controlling a drive assembly to move to a specific grid cell 14. The robotic arms 130 may include a local arm controller configured to receive and execute commands from the central control system, such as by controlling the robotic arms 130 to perform predetermined movements to move the batteries 80 between the robots 25, a specific charging bin 110, and a specific buffer bin 120 as needed. The battery exchange station may include a separate control system or be controlled by a central control system.

[0078] The central control system may wirelessly communicate with the robot 25 and the robotic arm 130 via wireless transmitters and receivers using known wireless communication technologies such as 4G, 5G, Wi-Fi, etc.

[0079] When the battery 80 in the robot 25 has been depleted beyond a threshold state of charge (as indicated by the BMS), the robot controller can report this to the central control system, which can then command the robot 25 to move to a designated grid cell 14a to perform a battery replacement.

[0080] The central control system is configured to track which charging bays 110 are occupied by batteries 80 (or to determine occupancy directly via sensors, for example), and to track the state of charge of each battery 80 (e.g., via each battery's BMS) to determine which specific battery 80 in the charging bay 110 should be swapped with a depleted battery 80 in the robot 25. For example, the central control system may be configured to command the robotic arm 130 to swap a depleted battery 80 in the robot 25 with the charged battery 80 in the charging bay 110 having the highest state of charge.

[0081] The control system described above is only one example of how the control system of the storage and retrieval system may be arranged, and other ways of distributing control of the robot 25 and the robotic arm 130 will be apparent to those skilled in the art.

[0082] The battery exchange station is not limited to the precise forms described above, and various modifications and variations falling within the scope of the claims will be apparent to those skilled in the art.

[0083] For example, although each buffer bin 120 described above is in the form of a receptacle for receiving the battery 80, each buffer bin 120 may take any form suitable for temporarily placing the battery 80 in a specific location. For example, each buffer bin 120 may simply be a specific area on a flat surface on which the battery 80 is placed. However, the receptacle is useful for securely holding the battery 80 while the battery 80 is in the buffer bin 120.

[0084] Furthermore, the buffer bin 120 does not necessarily need to be disposed on the same support structure (ie, the cabinet 102 ) as the charging bin 110 , but may be disposed on a separate support structure adjacent to the cabinet 102 .

[0085] Although the above-mentioned system is a system in which the battery 80 is received in the robot 25 and the battery exchange station 100 in a downward direction, the above-mentioned method of replacing the battery 80 is not limited to inserting and removing the battery 80 in the vertical direction, and can be applied to systems in which the battery 80 is inserted and removed in other directions, such as horizontally.

[0086] Furthermore, the above-described method of replacing batteries 80 is applicable not only to the above-described storage and retrieval system, but is generally applicable to any system in which rechargeable batteries or other power sources are exchanged between a battery-powered device (e.g., an electric vehicle) and an exchange station where the battery is charged.

[0087] The present invention may also be defined by the following clauses: A. A method of exchanging a first rechargeable battery with a second rechargeable battery, wherein the first rechargeable battery is located in a battery-powered device and the second rechargeable battery is located in a charging bay configured to charge the battery, the method comprising the steps of: (i) removing the first rechargeable battery from the device and placing it in a buffer compartment; (ii) removing the second rechargeable battery from the charging compartment and placing it in the device; and (iii) taking out the first rechargeable battery from the buffer compartment and placing it in the charging compartment.

[0088] B. A method of exchanging a first rechargeable battery with a second rechargeable battery, wherein the first rechargeable battery is located in a battery-powered device and the second rechargeable battery is located in a charging bay configured to charge the battery, the method comprising the steps of: (i) removing the second rechargeable battery from the charging compartment and placing it in a buffer compartment; (ii) removing the first rechargeable battery from the device and placing it in the charging compartment; and (iii) removing the second rechargeable battery from the buffer compartment and placing it in the device.

[0089] C. A method according to clause A or clause B, wherein steps (i)-(iii) are performed by a robotic arm.

[0090] D. A method according to clause C, wherein steps (i)-(iii) are performed by the same robotic arm.

[0091] E. A battery exchange station comprising: one or more charging bays configured to receive and charge batteries; one or more surge tanks; and A robotic arm configured to exchange a first rechargeable battery located in the device with a second battery located in one of the charging bays by performing the method of any one of clauses A to D.

[0092] F. A battery exchange station according to item E, wherein each charging compartment includes an electrical connector for connecting to a battery received in the charging compartment, and wherein the battery exchange station further includes one or more battery chargers, each electrical connector being electrically coupled to a corresponding battery charger.

[0093] G. The battery exchange station of clause E or clause F, wherein each buffer bin is not configured to charge a battery received therein.

[0094] H. A battery exchange station according to any one of clauses E to G, wherein the one or more buffer compartments are lower than the one or more charging compartments.

[0095] I. A storage and retrieval system comprising: A storage structure, the storage structure comprising: a plurality of horizontal members arranged to form a grid pattern defining a plurality of grid cells; a plurality of upright members configured to support the horizontal members from below to define a storage area below the grid cells for storing stacks of storage containers; a track structure positioned on top of the horizontal members, wherein the track structure includes a plurality of tracks arranged to form a grid pattern corresponding to the grid pattern formed by the horizontal members; and One or more load handling devices, each load handling device comprising: a drive assembly configured to move the load handling device on the track structure; a container retaining assembly configured to releasably retain a storage container from above; and a lifting assembly configured to raise and lower the container holding assembly to allow the load handling device to lift and lower storage containers into and out of the storage structure and the passageway via the grid cells; One or more battery exchange stations as described in any of clauses E to H, wherein each battery exchange station is located adjacent to or on the track structure.

Claims

1. A battery exchange station (100) for charging a plurality of batteries (80), each of the plurality of batteries including a battery management system (BMS), the battery exchange station comprising: i) a cabinet (102), the cabinet (102) including a plurality of battery chargers (114); ii) a plurality of bins, each bin configured to receive a battery, the plurality of bins being grouped into: a) a first grouping of bays, the first grouping comprising a plurality of charging bays (110), each of the plurality of charging bays comprising an electrical connector (112) for connecting to a battery received in the charging bay, each electrical connector being electrically coupled to a respective one of the plurality of battery chargers; b) a second grouping of bins, the second grouping comprising one or more non-charging buffer bins (120), each of the one or more non-charging buffer bins comprising a coupling means configured to establish communication with a BMS of a battery received in the non-charging buffer bin; and iii) a robotic arm (130) configured to exchange a battery located in the battery-powered device with a battery located in one of the plurality of charging bays.

2. The battery exchange station (100) according to claim 1, wherein The cabinet (102) is a single body.

3. The battery exchange station (100) according to claim 1 or 2, wherein: The plurality of bins are accommodated in the cabinet.

4. The battery exchange station (100) according to claim 3, wherein: Each of the plurality of bins is in the form of a receptacle having an opening in a top surface of the cabinet (102) to allow a battery (80) to be received in the receptacle in a vertical orientation.

5. The battery exchange station (100) according to claim 4, wherein: The cabinet (102) includes a first top surface and a second top surface, and a corresponding opening of each of the plurality of charging compartments (110) in the first group is located in the first top surface, and a corresponding opening of each of the one or more non-charging buffer compartments (120) in the second group is located in the second top surface.

6. The battery exchange station (100) according to claim 5, wherein: The second top surface of the cabinet (102) is at a lower vertical height than the first top surface of the cabinet.

7. A battery exchange station (100) according to any one of the preceding claims, wherein The ratio of the number of charging buffer bins (110) in the first group to the number of non-charging buffer bins (120) in the second group is between 2:1 and 10:

1.

8. The battery exchange station (100) according to claim 7, wherein: The ratio of the number of charging buffer bins (110) in the first group to the number of non-charging buffer bins (120) in the second group is 4:

1.

9. The battery exchange station (100) according to any one of the preceding claims, wherein One or more of the plurality of bins include one or more sensors to detect the presence of batteries in the bins.

10. The battery exchange station (100) according to any one of the preceding claims, wherein One or more of the plurality of bins includes a visual indicator of a state of charge of a battery received within the bin.

11. The battery exchange station (100) according to any one of the preceding claims, further comprising a control system, the control system being configured to: i) determining a state of charge of a battery (80) received within one of the plurality of non-charging buffer compartments (120); and ii) if the state of charge of the battery is below a predetermined threshold charge level, instructing the robotic arm to move the battery from the non-charging buffer bin (120) to one of the plurality of charging bins (110).

12. The battery exchange station (100) according to claim 11, wherein The control system is further configured as follows: i) determining whether the temperature of the battery (80) in any one of the plurality of bins exceeds a predetermined temperature threshold and / or whether the current of the battery in any one of the plurality of bins exceeds a predetermined current; and ii) activating a switch to disconnect the plurality of battery chargers (114) from the plurality of charging bays (110) if the temperature of the battery exceeds a predetermined temperature threshold and / or the current of the battery exceeds a predetermined current.

13. A storage and retrieval system comprising: A storage structure (1), comprising: a plurality of horizontal members (5, 7) arranged to form a grid pattern defining a plurality of grid cells (14); a plurality of upright members (3) configured to support the horizontal members from below to define a storage area below the grid cells for storing stacks of storage containers (9); a track structure located on top of the horizontal member, wherein the track structure includes a plurality of tracks (17, 19) arranged to form a grid pattern corresponding to the grid pattern formed by the horizontal member; and One or more load handling devices (25), each load handling device comprising: a drive assembly configured to move the load handling device on the track structure; a container retaining assembly (37) configured to releasably retain a storage container from above; and a lifting assembly (33) configured to raise and lower the container holding assembly to allow the load handling device to lift and lower storage containers into and out of the storage structure and the passageway via the grid cells; One or more battery exchange stations (100) according to any one of claims 1 to 12, wherein each battery exchange station is positioned next to or on the track structure.

14. A method of exchanging a first battery (80a) with a second battery (80b) at a battery exchange station (100) as defined in any one of claims 1 to 12, wherein: The first battery is located in a battery-powered device, and the second battery is located in a charging compartment (110). The method comprises the following steps: (iv) removing a first battery from the battery-powered device and placing it in a non-charging buffer compartment (120); (v) removing the second battery from the charging compartment and placing it in the battery-powered device; and (vi) taking out the first battery from the non-charging buffer compartment and placing it in the charging compartment.

15. A method of exchanging a first battery (80a) with a second battery (80b) at a battery exchange station (100) as defined in any one of claims 1 to 12, wherein: The first battery is located in a battery-powered device, and the second battery is located in a charging compartment (110). The method comprises the following steps: (iv) removing the second battery from the charging compartment and placing it in a non-charging buffer compartment (120); (v) removing the first battery from the battery-powered device and placing it in the charging compartment; and (vi) removing the second battery from the non-charging buffer compartment and placing it in the battery-powered device.

16. The method according to claim 14 or 15, wherein steps (i)-(iii) are performed by a robotic arm (130).

17. The method of claim 16, wherein all steps (i)-(iii) are performed by the same robotic arm (130).

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