Material handling vehicle battery with isolated switching devices

Abstract

An industrial battery design for a material handling vehicle. The battery includes: a battery cell; a heater for supplying heat to the battery cell; a temperature sensor for monitoring a temperature of the battery cell; a first switching device through which power for the heater is routed; a second switching device through which power for the heater is not routed; and a controller. The controller includes circuitry configured to receive temperature data indicative of a temperature of the battery cell from the temperature sensor and to turn on the first switching device without turning on the second switching device based on the temperature data received from the temperature sensor.

Description

Cross Reference to Related Applications

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application Serial No. 63 / 688,196, filed August 28, 2024, which is incorporated by reference herein in its entirety. BACKGROUND

[0002] Various types of batteries have been used to provide power to material handling vehicles (MHVs) and in other industrial applications. However, improved industrial battery designs are generally desired. SUMMARY

[0003] The present disclosure generally relates to industrial battery designs including phase-isolated switching devices.

[0004] In one aspect, the present disclosure provides a material handling vehicle. The material handling vehicle includes a battery compartment and a battery disposed in the battery compartment. The battery includes a battery cell, a heater to provide heat to the battery cell, a temperature sensor to monitor a temperature of the battery cell, a first switching device through which power for the heater is routed, a second switching device through which power for the heater is not routed, and a controller. The controller includes circuitry configured to receive temperature data indicative of the temperature of the battery cell from the temperature sensor and to open the first switching device without opening the second switching device based on the temperature data received from the temperature sensor.

[0005] In another aspect, the present disclosure provides a battery. The battery includes a battery cell, a heater to provide heat to the battery cell, a temperature sensor to monitor a temperature of the battery cell, a first switching device through which power for the heater is routed, a second switching device through which power for the heater is not routed, and a controller. The controller includes circuitry configured to receive temperature data indicative of the temperature of the battery cell from the temperature sensor and to open the first switching device without opening the second switching device based on the temperature data received from the temperature sensor.

[0006] In yet another aspect, the present disclosure provides a battery. The battery includes a battery cell, a heater to provide heat to the battery cell, a temperature sensor to monitor a temperature of the battery cell, a first switching device through which power for the heater is routed, a second switching device through which power for the heater is not routed, and a controller. The controller includes circuitry configured to receive temperature data indicative of the temperature of the battery cell from the temperature sensor, open the first switching device and not the second switching device based on the temperature data received from the temperature sensor, and in response to detecting a fault independent of the temperature of the battery cell, open the second switching device and not the first switching device.

[0007] The foregoing and other aspects and advantages of the present disclosure will be apparent from the following description. In the description, reference is made to the accompanying drawings which form a part hereof, and in which are shown by way of illustration preferred configurations in accordance with the present disclosure. Such configurations do not necessarily represent the full scope of the present disclosure, and therefore reference to the claims and this specification is desirable for interpreting the scope of the present disclosure. BRIEF DESCRIPTION OF DRAWINGS

[0008] The present disclosure will be better understood with reference to the following detailed description of specific embodiments, and to the drawings in which:

[0009] Figure 1 is a perspective view of an example materials handling vehicle including a battery compartment for an industrial battery in accordance with some aspects of the present disclosure.

[0010] Figure 2 is a block diagram illustrating components of an example battery that can be used with Figure 1 a materials handling vehicle of

[0011] Figure 3 is a diagram illustrating an example implementation of a battery in accordance with some aspects of the present disclosure. Figure 2

[0012] Figure 4 is a diagram illustrating an example battery housing for a battery in accordance with some aspects of the present disclosure. Figure 2

[0013] Figure 5 is a diagram illustrating example components of an electronic tray of a battery in accordance with some aspects of the present disclosure. Figure 2

[0014] Figure 6 is a diagram illustrating an example battery in accordance with some aspects of the present disclosure.​​​Figure 2 Example schematic diagram of various components of a battery.

[0015] Figure 7 is a flowchart illustrating an example process for disconnecting components of a battery using phase-isolated switching devices in accordance with some aspects of the present disclosure. Figure 2 is a flowchart illustrating an example process for disconnecting components of a battery using phase-isolated switching devices in accordance with some aspects of the present disclosure. DETAILED DESCRIPTION

[0016] Before any aspects of the application are explained in detail, it is to be understood that the application is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the accompanying drawings. The application is capable of other aspects and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and not of limitation. As used herein, the use of "including," "comprising," or "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms "mounted," "connected," "supported," and "coupled," and variations thereof, are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, "connected" and "coupled" are not restricted to physical or mechanical connections or couplings.

[0017] The following discussion is presented to enable a person skilled in the art to make and use aspects of the present disclosure. Various modifications to the aspects will be readily apparent to those skilled in the art, and the generic principles defined herein can be applied to other aspects and applications without departing from aspects of the present disclosure. Thus, aspects of the present disclosure are not intended to be limited to the aspects shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like reference numerals in different figures represent like elements throughout the several figures. The drawings, which are not necessarily to scale, depict selected aspects and are not intended to limit the scope of aspects of the present disclosure. The skilled artisan will recognize that the examples provided herein have many useful alternatives and that the herein disclosed aspects can be practiced without resorting to the details of the following examples.

[0018] It should also be appreciated that material handling vehicles (MHVs) are designed in various classes and configurations to perform various tasks. It will be apparent to those skilled in the art that the present disclosure is not limited to any particular MHV and can also be provided with various other types of MHV classes and configurations including, for example, lift trucks, fork trucks, reach trucks, SWING Vehicles, turret trucks, side loaders, counterbalanced lift trucks, pallet stacker trucks, order pickers, transfer vehicles, tractors, and man-up trucks, and can be found in warehouses, factories, shipyards, and, in general, anywhere that it is often necessary to transport pallets, bulk packages, or loads of goods from one place to another. The various systems and methods disclosed herein are applicable to any of the following: operator-controlled material handling vehicles, pedestrian-controlled material handling vehicles, remotely-controlled material handling vehicles, and autonomously-controlled material handling vehicles. Further, the various systems and methods disclosed herein are applicable to other vehicles, such as cars, buses, trains, tractor trailers, agricultural vehicles, factory vehicles, etc.

[0019] Reference is made to Figure 1 According to some aspects of the present disclosure, a perspective view showing an example material handling vehicle 100 is shown. In the example of Figure 1 The material handling vehicle 100 is shown as including a battery compartment 102, a power section 103, and a handle 104. The power section 103 can include any suitable power electronics and other components for operating the material handling vehicle 100. The handle 104 can be used by an operator of the material handling vehicle 100 to maneuver the material handling vehicle 100. The battery compartment 102 can be used to mount and house an industrial battery, such as the various modular industrial battery configurations described below, that provides power to the material handling vehicle 100. The battery compartment 102 in the material handling vehicle 100 can include terminals, ports, wiring, and other components for connecting the industrial battery to the material handling vehicle 100. It should be understood that battery compartments similar to the battery compartment 102 can be provided in various locations and configurations depending on the type and configuration of the material handling vehicle.

[0020] Reference is made to Figure 2 According to some aspects of the present disclosure, a block diagram showing components of an example battery 200 that can be used with the material handling vehicle 100 is shown. In particular, the battery 200 can be a sealed battery and can be disposed within the battery compartment 102 of the material handling vehicle 100. As Figure 2As shown, the battery 200 can include a battery cell row 230 and a battery cell row 240. The battery 200 can also include a heater 238 that can be used to heat the battery cell row 230 and a temperature sensor 239 that can be used to generate temperature data associated with the battery cell row 230. Similarly, the battery 200 can include a heater 248 that can be used to heat the battery cell row 240 and a temperature sensor 249 that can be used to generate temperature data associated with the battery cell row 240. The battery 200 is also shown to include a controller 222 and three main switching devices: a switching device 202, a switching device 204, and a switching device 206. Finally, the battery 200 is shown to include the controller 222.

[0021] The battery cell row 230 and the battery cell row 240 can include any number of battery cells. Moreover, in some examples, the battery 200 can include only one of the battery cell row 230 or the battery cell row 240, such that the battery 200 can include only a single row of one or more battery cells. Additionally, in some examples, the battery 200 can include additional rows of one or more battery cells in addition to the battery cell row 230 and the battery cell row 240, such that the battery 200 can include three or more rows of battery cells. The battery cell row 230 can include one or more lithium iron phosphate (LFP) battery cells (sometimes referred to as “modules”), and the battery cell row 240 can also include one or more LFP battery cells.

[0022] The heater 238 and the heater 248 can be implemented using various suitable types of heater configurations. The temperature sensor 239 and the temperature sensor 249 can likewise be implemented using various suitable types and configurations of temperature sensors (e.g., using a thermistor, a thermocouple, a resistance temperature detector (RTD), a semiconductor, etc.). Generally, the heater 238 can receive electrical power and provide heat to the battery cell row 230, and the heater 248 can receive electrical power and provide heat to the battery cell row 240. In particular, because the battery 200 can be disposed in the battery bay 102 and / or can be sealed within a battery housing (as described in detail below), the battery cell row 230 and / or the battery cell row 240 can be in a low temperature state after periods of inactivity. Accordingly, the heater 238 and the heater 248 can be used to provide heat to the battery cell row 230 and the battery cell row 240 in these scenarios to help the battery 200 reach a stable operating state more quickly.

[0023] The temperature sensor 239 can be disposed within the battery 200 in various suitable configurations such that the temperature sensor 239 can generate and provide temperature data associated with the battery cell row 230 to the controller 222. The temperature sensor 249 can likewise be disposed within the battery 200 in various suitable configurations such that the temperature sensor 249 can generate and provide temperature data associated with the battery cell row 240 to the controller 222. The controller 222 can then use the temperature data from the temperature sensor 239 and the temperature sensor 249 to control operation of the heater 238 and the heater 248 (e.g., by turning the heater 238 and the heater 248 on or off, by controlling a level of heating provided by the heater 238 and the heater 248, by opening the switch device 202, the switch device 204, and / or the switch device 206 to cut power to the heater 238 and the heater 248, etc.).

[0024] The switch device 202, the switch device 204, and the switch device 206 can each be opened and closed by the controller 222 to disconnect components of the battery 200 (e.g., from a power source) under certain operating conditions determined by the controller 222. The switch device 202, the switch device 204, and the switch device 206 can use various suitable types and configurations of switch devices (e.g., contactors, solid state switches, etc.). The switch device 202, the switch device 204, and the switch device 206 can be the primary wear items on the battery 200, and thus the controller 222 can be configured to only open one of the switch device 202, the switch device 204, and the switch device 206 at a time in response to detecting certain conditions occurring within the battery 200 (e.g., based on sensor data). In contrast to a battery that opens all of the switches in response to detecting a fault or a battery that uses thermal fuses to disconnect the heaters, this sequential switch device control of the switch device 202, the switch device 204, and the switch device 206 by the controller 222 can allow the controller 222 to reduce the amount of wear on the switch device 202, the switch device 204, and the switch device 206, and predict which of the switch device 202, the switch device 204, and the switch device 206 will wear out the fastest. Specifically, the controller 222 can determine which of the switch device 202, the switch device 204, and the switch device 206 will wear out the fastest based on the number of times the controller 222 opens the switch device 202, the switch device 204, and the switch device 206 (the more times it is opened, the more likely it is to wear out). The controller 222 can record the number of times it opens the switch device 202, the switch device 204, and the switch device 206 in memory.

[0025] In particular, the switch device 202 can be a positive charger side switch device of the battery 200. Power for the heater 238 and the heater 248 can be routed through the switch device 202, but not through the switch devices 204 or 206. The controller 222 can receive temperature data from the temperature sensor 239 and the temperature sensor 249, and can open the switch device 202 (without opening the switch device 204 or the switch device 206) based on the temperature data. For example, the controller 222 can open the switch device 202 (without opening the switch device 204 or the switch device 206) in response to determining that the temperature data from the temperature sensor 239 and the temperature sensor 249 exceeds a threshold temperature level.

[0026] The threshold temperature level can be set and / or adjusted based on various factors during operation of the battery 200. Additionally, the controller 222 can be configured to open the switch device 202 based on temperature data received from other temperature sensors included in the battery 200, specifically in addition to the temperature sensor 239 and the temperature sensor 249, to cut power to the heater 238 and the heater 248. For example, the threshold temperature level can be a temperature level at which heating of the battery cell row 230 and / or the battery cell row 240 is no longer needed. The threshold temperature level can vary based on various factors, such as the type and modular configuration of battery cells used in the battery 200 (e.g., capacity, energy density, voltage range, nominal voltage, weight, lx2 cell configuration, 2x2 cell configuration, 2x3 cell configuration, etc.) and the sampling time period used by the controller 222 for the temperature sensor 239, the temperature sensor 249, and / or other temperature sensors included in the battery 200.

[0027] In particular, the switch device 204 can be a positive truck side switch device of the battery 200, and the switch device 206 can be a redundant negative switch device of the battery 200, specifically. The controller 222 can be configured to open the switch device 204 (without opening the switch device 202 or the switch device 206) in response to detecting various faults and conditions that can occur within the battery 200. For example, based on sensor data and / or communications, the controller 222 can open the switch device 204 (without opening the switch device 202 or the switch device 206) in response to detecting a communication loss fault, a short circuit fault, a low charge state condition, and / or other faults and conditions that can occur within the battery 200. In particular, the controller 222 can open the switch device 204 in response to detecting a fault that is independent of the temperature of the battery cell row 230 or the battery cell row 240.

[0028] Similarly, the controller 222 can also be configured to open the switch device 206 (without opening the switch device 202 or the switch device 204) in response to detecting various types of faults and conditions that can occur within the battery 200. For example, based on sensor data and / or communications, the controller 222 can open the switch device 206 (without opening the switch device 202 or the switch device 204) in response to detecting a communication loss fault, a short circuit fault, a low charge state condition, and / or other faults and conditions that can occur within the battery 200. Additionally, since the switch device 206 can be used as a redundant switch device, in some scenarios, the controller 222 can be configured to open the switch device 206 in response to detecting a fault or condition associated with the switch device 202 and / or the switch device 204 (e.g., a mechanical fault due to wear, a communication loss fault, etc.).

[0029] The controller 222 can be implemented in various ways within the battery 200, including by using one or more separate controller devices. For example, the controller 222 can include various suitable types of processing circuitry (e.g., one or more central processing units (CPUs), etc.) and memory (e.g., volatile, non-volatile, random access memory (RAM), read only memory (ROM), electrically erasable programmable read only memory (EEPROM), etc.). The memory can include one or more non-transitory machine-readable storage media having stored therein instructions that, when executed by the processing circuitry, cause the processing circuitry to perform various operations according to the instructions. The controller 222 can also include various suitable types of communication interfaces (e.g., a controller area network (CAN) interface for communicating via a CAN bus, an Ethernet interface, a serial communication interface, etc.) for communicating via various suitable protocols. The controller 222 can then communicate with various components of the battery 200 (e.g., the switch device 202, the switch device 204, the switch device 206, the heater 238, the temperature sensor 239, the heater 248, the temperature sensor 249, etc.), with the material handling vehicle 100 (e.g., a vehicle controller of the material handling vehicle 100, etc.), and / or with other computing devices (e.g., servers, personal computing devices, etc.).

[0030] Referring to Figure 3 According to some aspects of the present disclosure, a diagram showing an example implementation of the battery 200 is shown. Specifically, as shown in FIG. 3, the battery 200 can include a controller 222, a switch device 202, a switch device 204, a switch device 206, a heater 238, a temperature sensor 239, a heater 248, a temperature sensor 249, and a battery 250. Figure 3The illustrated embodiment of the battery 200 includes both the battery cell row 230 and the battery cell row 240, and each of the battery cell row 230 and the battery cell row 240 includes three LFP battery cells. Specifically, as illustrated, the battery cell row 230 includes the battery cell 232, the battery cell 234, and the battery cell 236, and the battery cell row 240 includes the battery cell 242, the battery cell 244, and the battery cell 246. This 23-cell configuration illustrated is merely representative of one possible implementation of the battery 200. The design of the various components of the battery 200, including the switching device 202, the switching device 204, and the switching device 206, can provide for repeatable manufacturing for various types of modular battery cell configurations. For example, depending on the desired application (e.g., the type of materials handling vehicle, etc.), the battery 200 can instead include a 2x2 cell configuration, a 1x1 cell configuration, a 1x2 cell configuration, etc.

[0031] As Figure 3 illustrated, the battery 200 can also include a metal base plate 270. Depending on the intended application of the battery 200, the metal base plate 270 can be formed using various suitable metals (e.g., steel, aluminum, etc.), and can have different dimensions. The metal base plate 270 can generally provide a structure that serves as a base for the battery 200. Additionally, a lower metal tray 260 can be formed on or otherwise disposed above the metal base plate 270. Depending on the intended application of the battery 200, the lower metal tray 260 can likewise be formed using various suitable metals (e.g., steel, aluminum, etc.), and can have different dimensions. The battery cell row 240 including the battery cell 242, the battery cell 244, and the battery cell 246 can then be formed on or otherwise disposed above the lower metal tray 260. Furthermore, an intermediate metal tray can be disposed above the battery cell row 240 including the battery cell 242, the battery cell 244, and the battery cell 246. Depending on the intended application of the battery 200, the intermediate metal tray 250 can also be formed using various suitable metals (e.g., steel, aluminum, etc.), and can have different dimensions. The battery cell row 230 including the battery cell 232, the battery cell 234, and the battery cell 236 can then be formed on or otherwise disposed above the intermediate metal tray 250.

[0032] Then, as Figure 3As shown, the top tray 210 can be disposed above a battery cell row 230 that includes battery cell 232, battery cell 234, and battery cell 236. Depending on the intended application of the battery 200, the top tray 210 can likewise be formed using various suitable metals (e.g., steel, aluminum, etc.) and can have different dimensions. Finally, an electronics tray 220 can be formed on or otherwise disposed above the top tray 210. The electronics tray 220 can include various electronic and / or mechanical components for the battery 200, as will be described in further detail below. As noted, the electronics tray 220 can be an integral part of the top tray 210, or the electronics tray 220 can be separate from the top tray 210. In examples where the electronics tray 220 is separate from the top tray 210, the electronics tray 220 can be secured to the top tray 210 in various suitable manners (e.g., using various types of fasteners, etc.).

[0033] Referring to Figure 4 , according to some aspects of the present disclosure, a diagram is shown illustrating an example implementation of a battery housing 280 for the battery 200. The battery housing 280, along with the metal base plate 270, can be used to provide a sealed enclosure that protects the internal components of the battery 200 (e.g., the battery cell row 230, the battery cell row 240, the electronics tray 220, etc.) from environmental factors. For example, the sealed enclosure formed by the battery housing 280 and the metal base plate 270 can protect the internal components of the battery 200 from the ingress of dust, liquids, chemicals, and other potential contaminants. The battery housing 280 can be formed using various suitable materials (e.g., a curved sheet of steel, aluminum, etc.) and can be bolted to the metal base plate 270 to form the sealed enclosure, for example.

[0034] Also as Figure 4 shown, the battery 200 can include a cover assembly 290 that can be disposed above the battery housing 280. More specifically, the cover assembly can be positioned on a top surface of the battery housing 280 (e.g., the surface opposite the metal base plate 270) and secured (e.g., via bolting) to the battery housing 280. The battery housing 280, the cover assembly 290, and / or the metal base plate 270 can include components that help form the sealed enclosure, including, for example, gaskets, compression limiters, etc. In some examples, the metal base plate 270 and / or the cover assembly 290 can be considered part of the battery housing 280 itself. Depending on the particular modular configuration of the battery 200, the battery housing 280 can have different dimensions for a given application.

[0035] Referring to Figure 5 , according to some aspects of the present disclosure, a diagram is shown illustrating example components of the electronics tray 220. Specifically, Figure 5Top and bottom views of the electronic component tray 220 are shown. Figure Two As shown in the figure, the electronic component tray 220 may include a main controller 322, a sub-controller 324, an interface board 332, a communication board 334, a communication port 326, a main contactor 342, a series contactor 344, a heater relay 352, a system fuse 354, a shunt 356, and a Hall effect sensor 358. Each of these components of the electronic component tray 220 may be formed on the metal substrate 310 of the electronic component tray 220, such as... Figure 5 As shown. As mentioned above, as Figure 2 The controller 222 shown can be implemented in various ways. For example, the controller 222 may include both the main controller 322 and the sub-controller 324, or the controller 222 may include only the main controller 322, and other possible implementations.

[0036] Depending on the intended application of the battery 200, the metal substrate 310 of the electronics tray 220 can be formed using various suitable metals (e.g., steel, aluminum, etc.) and can have different dimensions. The metal substrate 310 typically provides a structure serving as the base of the electronics tray 220. The main controller 322 and the sub-controller 324 can be implemented using various suitable types of electronic controller components. The main controller 322 and the sub-controller 324 can each include various types of processing circuitry and various types of memory storing non-transient machine-readable instructions, which, when executed by the processing circuitry of the main controller 322 and the sub-controller 324 respectively, cause the main controller 322 and the sub-controller 324 to operate according to the machine-readable instructions. The main controller 322 can interact with the sub-controller 324, such that the main controller 322 acts as the initiator of control transactions, and the sub-controller 324 responds to communications received from the main controller 322. The main controller 322 and the sub-controller 324 can operate as separate modules, as part of the battery management system (BMS) of the battery 200.

[0037] Both interface board 332 and communication board 334 can be implemented as printed circuit boards (PCBs), among other possible implementations. Interface board 332 may include circuitry for providing various electronic interfaces between components of battery 200. For example, interface board 332 may include circuitry for providing an electronic interface between main controller 322 and sub-controller 324, and for providing an interface between controller 222 and various sensors included as part of battery 200 (e.g., for communicatively coupling controller 222 to sensors). Communication board 334 may include circuitry for providing communication between battery 200 and material handling vehicle 100 (e.g., an interface between battery 200 and one or more controllers on material handling vehicle 100). Communication port 336 may be communicatively coupled to interface board 332 and / or communication board 334, and communication port 336 may be used to form various electrical connections between battery 200 and external components and devices (e.g., for wiring battery 200 to one or more controllers on material handling vehicle 100, etc.).

[0038] The main contactor 342 may include any suitable number of primary contactors for disconnecting components of the battery 200 (e.g., for interrupting current in the circuit under certain operating conditions). For example, the main contactor 342 may include switchgear 202, switchgear 204, and switchgear 206. The series contactor 344 may similarly include any suitable number of contactors for disconnecting components of the battery 200 (e.g., for interrupting current in the circuit under certain operating conditions). The main contactor 342 may be shared across all modular configurations of the battery 200 (e.g., 1×1 cell configuration, 2×2 cell configuration, etc.), and the series contactor 344 may vary depending on the specific modular configuration of the battery 200 (e.g., for a smaller battery size, the series contactor 344 may include two contactors, while for a larger battery size, the series contactor 344 may include four contactors). Both the main contactor 342 and the series contactor 344 can be implemented using a variety of suitable types and configurations of contactors. Furthermore, in some applications, the main contactor 342 and the series contactor 344 can be implemented using other suitable components (e.g., different types of switches, relays, etc.). In some examples, the main contactor 342 may include switching device 202, switching device 204, switching device 206, and / or one or more additional contactors.

[0039] Heater relay 352 is typically used to control the operation of one or more heaters to provide heat to battery cell rows 230 and 240 (e.g., heaters 238 and 248). For example, the ability to provide heat to battery cell rows 230 and 240 via heaters 238 and 248 when battery 200 is energized can help battery 200 reach a stable operating state that might otherwise not be possible without one or more heaters. Heater relay 352 can be implemented using various suitable types and configurations of relays, and heaters can be implemented using various suitable types and configurations of heaters. Furthermore, in some applications, heater relay 352 can be implemented using other suitable components (e.g., different types of switches, contactors, etc.). Heater relay 352 can be connected to heaters 238 and 248 and operated by controller 222.

[0040] A system fuse 354 can be used in battery 200 to provide overcurrent protection for battery 200 by interrupting the current flowing through battery 200. Depending on the application of battery 200, system fuse 354 can be implemented using various types and configurations of fuses. Similarly, a shunt 356 can be used in battery 200 to provide further overcurrent protection for battery 200 by diverting the current flowing through battery 200. Shunt 356 can be used to measure the current flowing from one or more battery cells of battery 200 to a load (e.g., material handling vehicle 100) connected to battery 200. Depending on the application of battery 200, shunt 356 can also be implemented using various types and configurations of shunts. A Hall effect sensor 358 can be used in battery 200 to provide current sensing functionality and / or other types of sensing functionality. Depending on the application of battery 200, Hall effect sensor 358 can be implemented using various types and configurations of Hall effect sensors.

[0041] refer to Figure 6 According to some aspects of this disclosure, example schematic diagrams illustrating various components of the battery 200 are shown. Figure 6 The schematic diagram shows various example components of the electronic device tray 220, including heater relay 352, system fuse 354, shunt 356, and Hall effect sensor 358. Figure 6The schematic diagram also shows various additional example components, including charger guide circuit interface 362, proximity sensor 364, charger guide circuit interface 367, proximity sensor 368, switching device 202, parallel series disconnect device 374, switching device 204, switching device 206, terminal circuit 382, ​​truck control interface 384, truck wake-up interface 386, truck control interface 388, fan disconnect device 390, first charger connector port 392, second charger connector port 394, and truck connector port 396. Figure 6 The schematic diagram shown represents only one possible implementation of various aspects of this disclosure in relation to battery 200, and other implementations are contemplated and possible.

[0042] As described, the main contactor 342 may include, for example, switching devices 202, 204, and 206, such as... Figure 6 As shown. In addition to the functions described in detail above, the switching device 202 can also be used to connect to the battery 200 (e.g., via one or more charger devices) that may be connected to the battery 200. Figure 6 The example charger connector ports 392 and 394 shown in the schematic diagram can disconnect components of battery 200 in the event of an overcurrent condition. For example, controller 222 can receive current data from Hall effect sensor 358 and / or other sensors included in battery 200, and turn on switch device 202 in response to determining that the current data exceeds one or more thresholds. In addition to the functions described in detail above, switch device 204 can also be used to disconnect components of battery 200 and / or material handling vehicle 100 in the event of an overcurrent condition that may occur within battery 200 and / or material handling vehicle 100. For example, controller 222 can receive data from Hall effect sensor 358 and / or other sensors included in battery 200, and turn on switch device 204 in response to determining that the sensor data exceeds one or more thresholds. In addition to the functions described in detail above, switch device 206 can also be used to disconnect components of battery 200 and / or material handling vehicle 100 in the event of an overcurrent condition that may occur within battery 200 and / or material handling vehicle 100. For example, controller 222 may receive data from Hall effect sensor 358 and / or other sensors included in battery 200, and turn on switching device 206 in response to determining that sensor data exceeds one or more thresholds.

[0043] The series contactor 344 may include, for example, Figure 6The series disconnect contactor 374 is shown. The series disconnect contactor 374 can be used to cut off the current flowing to and / or from the battery cells of battery 200 in the event of an overcurrent condition that may occur within battery 200, thereby disconnecting battery 200 and / or material handling vehicle 100. For example... Figure 6 As illustrated in the schematic diagram, the series disconnect contactor 374 may include a first contactor connected to a first row of battery cells (e.g., battery cell row 230) and a second contactor connected in parallel with the first contactor to a second row of battery cells (e.g., battery cell row 240). For example, the controller 222 may receive data from the Hall effect sensor 358 and / or other sensors included in the battery 200, and open one or more of the series disconnect contactors 374 in response to determining that the sensor data exceeds one or more thresholds.

[0044] A first charger connector port 392 is used to connect a first charger device to the battery 200, and a second charger connector port 394 is used to connect a second charger device to the battery 200. A truck connector port 396 is used to connect the battery 200 to a material handling vehicle 100 (e.g., to a controller on the material handling vehicle 100). A charger guide circuit interface 362 may include circuitry for providing a charging interface between the first charger device and the battery 200, and a charger guide circuit interface 367 may include circuitry for providing a charging interface between the second charger device and the battery 200. A proximity sensor 364 provides proximity sensing functionality, enabling the controller 222 to detect the presence of a connection between the first charger device and the battery 200, and a proximity sensor 368 provides proximity sensing functionality, enabling the controller 222 to detect the presence of a connection between the second charger device and the battery 200.

[0045] Terminal circuitry 382 may be included in battery 200 to provide an endpoint (terminal) of a communication bus (e.g., CAN bus) for battery 200. Truck control interface 384 may be included in battery 200 to provide a control interface between battery 200 and material handling vehicle 100. Truck wake-up interface 386 may be used to transmit a wake-up signal (e.g., a power-on signal) to battery 200 via material handling vehicle 100 (e.g., when material handling vehicle 100 is powered on). Truck control interface 388 may also be included in battery 200 to provide a control interface between battery 200 and material handling vehicle 100. Specifically, truck control interface 384 may provide a common standard interface (PSI) option, while truck control interface 388 may provide a power source limited (PSL) interface option for battery 200. Fan disconnect device 390 may be controlled by controller 222 to operate (e.g., turn on / off, etc.) one or more fans included in battery 200 to provide heat transfer within battery 200.

[0046] The design of battery 200 may include two physically separated BMS domains that are communicatively linked (e.g., via a CAN bus, etc.). For example, controller 222 may include a first control device mounted on the high-voltage backplane of battery 200 and a second control device separated from the first control device and located on the low-energy side of the wiring harness of battery 200 (and other possible mounting locations). The first control device may handle disconnection functions (e.g., process 700, etc.), and the second control device may handle communication functions (e.g., display docking, data logging, fleet telematics, etc.). This functional partitioning of controller 222 can provide advantages in a variety of applications.

[0047] The design of battery 200 may also include storage features that allow battery 200 to retain various types of historical information. For example, controller 222 may be configured to read historical information associated with battery 200 from two separate sources: onboard non-volatile memory (NVM) and a removable memory card. Controller 222 may verify the integrity of records retrieved from both the onboard NVM and the removable memory card in various ways. If the verified records differ, controller 222 may be configured to use the record with the most recent timestamp and overwrite the record with the second most recent timestamp to synchronize the records. The historical information included in the records may include various parameters associated with battery 200, including operating hour counts, ampere-hour (Ah) delivery counts, and / or cycle counts, among other possibilities.

[0048] Additionally, the design of battery 200 may include features that allow controller 222 to electronically determine the state of various switching devices (e.g., switch 202, switch 204, switch 206, etc.) and to determine open-circuit and short-circuit conditions. Specifically, controller 222 may be configured to make these determinations based on various resistance values ​​associated with battery 200. For example, consider an implementation in which switch 202 and switch 204 are connected in parallel. In such an example, a first resistor may be connected in series with switch 202, a second resistor may be connected in series with switch 204, and a third resistor may be connected in parallel with both switch 202 and switch 204. Controller 222 may then be connected to the first, second, and third resistors such that controller 222 receives a single resistance input for both switching devices (in this case, switch 202 and switch 204).

[0049] In such examples, the resistance values ​​of the first, second, and third resistors can be selected so that the controller 222 can use a single resistance input to determine the state of the switching device 202 and the switching device 204. Furthermore, the resistance values ​​of the first, second, and third resistors can be selected so that the controller 222 can use a single resistance input to determine open-circuit and short-circuit conditions. Let's consider a scenario where the first resistor is selected to have a value of 4120 ohms, the second resistor is selected to have a value of 1690 ohms, and the third resistor is selected to have a value of 1900 ohms. In this scenario, if the resistance input is within a first range (e.g., greater than 2000 ohms), controller 222 can determine that an open circuit exists; if the resistance input is within a second range (e.g., between 1600 ohms and 2000 ohms), controller 222 can determine that both switch 202 and switch 204 are in the open state; if the resistance input is within a third range (e.g., between 1200 ohms and 1600 ohms), controller 222 can determine that switch 202 is in the closed state and switch 204 is in the open state. The controller 222 can determine that switch 202 is in the open state and switch 204 is in the closed state if the resistance input is in the fourth range (e.g., between 800 ohms and 1200 ohms); if the resistance input is in the fifth range (e.g., between 400 ohms and 800 ohms), the controller 222 can determine that both switch 202 and switch 204 are in the closed state; and if the resistance input is in the sixth range (e.g., below 400 ohms), the controller 222 can determine that a short circuit condition exists.

[0050] Furthermore, the design of battery 200 may include features that allow controller 222 to diagnose the current sensing functionality provided via shunt 356. In some examples, shunt 356 may be a 1200-amp, 50-millivolt shunt (and other possible implementations) directly connected to controller 222 (e.g., via a first connection to the battery side of shunt 356 and a second connection to the load side of shunt 356, etc.). For example, controller 222 may use such a direct connection to shunt 356 to sense the voltage on shunt 356, perform analog-to-digital conversion associated with shunt 356, and perform overcurrent diagnostics. Controller 222 may detect faults associated with shunt 356 by controlling various components of battery 200 and evaluating the resulting current measurements associated with shunt 356. For example, upon entering a energized state of battery 200, controller 222 may close switch device 206 and control heater relay 352 to turn on one or more heaters of battery 200. Then, controller 222 can determine whether the change in current sensed by shunt 356 within a first time period (e.g., 5 seconds, 7 seconds, etc.) after one or more heaters are turned on exceeds a first threshold amount (e.g., 9 amps, 12 amps, 15 amps, etc.). If the change in current sensed by shunt 356 within the first time period does not exceed the first threshold amount, controller 222 can detect a fault associated with shunt 356. In response to detecting a fault associated with shunt 356, controller 222 can turn on switching devices 202, 204, and / or 206.

[0051] Furthermore, if the current sensed by shunt 356 is within a certain range (e.g., from -9 amps to 10 amps, etc.) for a second time period (e.g., 0.8 hours, 1 hour, etc.), controller 222 can perform various actions to diagnose shunt 356. For example, in response to determining that the current sensed by shunt 356 is within that range for the second time period, controller 222 can control heater relay 352 to turn off one or more heaters of battery 200 for a third time period (e.g., 5 seconds, 7 seconds, etc.), and store a first current measurement value associated with shunt 356 after the third time period. Then, after the third time period, controller 222 can control heater relay 352 to turn on one or more heaters of battery 200 for a fourth time period (e.g., 5 seconds, 7 seconds, etc.), and store a second current measurement value associated with shunt 356 after the fourth time period. Controller 222 can then compare the first current measurement value with the second current measurement value to detect a fault associated with shunt 356. For example, controller 222 may detect a fault associated with shunt 356 in response to determining that the difference between a first current measurement and a second current measurement is less than a second threshold amount (e.g., 7 amps, 9 amps, 10 amps, etc.). Then, in response to detecting the fault associated with shunt 356, controller 222 may turn on switchgear 202, switchgear 204, and / or switchgear 206.

[0052] refer to Figure 7 According to some aspects of this disclosure, a flowchart illustrating an example process 700 for disconnecting components of battery 200 using phase-isolated switching devices is shown. For example, process 700 may be performed at least in part by controller 222. Process 700 typically includes: turning on switching device 202 (without turning on switching device 204 or switching device 206) based on temperature data received by controller 222 to cut off power to heater 238 and / or heater 248. For example, controller 222 may receive temperature data from temperature sensor 239 and / or temperature sensor 249. By implementing process 700, wear on switching devices 202, 204, and 206 can be reduced, and controller 222 can predict which of switching devices 202, 204, and 206 will wear the fastest by recording the number of times switching devices 202, 204, and 206 are turned on.

[0053] At step 710, process 700 may include routing power for the heaters of the battery cells of the battery via a first switching device of the battery. For example, when manufacturing battery 200, power for the heaters 238 of the battery cell row 230 may be routed via switching device 202. However, battery 200 may also include a second switching device, such as switching device 204. When manufacturing battery 200, power for the heaters 238 of the battery cell row 230 may not be routed via switching device 204, such that switching device 204 is at least partially isolated from switching device 202. Furthermore, controller 222 may be configured to turn on and off switching device 202 (e.g., by sending control signals to switching device 202) without turning on or off switching device 204, such that controller 222 may be configured to implement sequential switching device control with respect to switching devices 202 and 204.

[0054] At step 720, process 700 may include receiving temperature data associated with the battery cell from a temperature sensor. For example, controller 222 may receive temperature data associated with battery cell 232, battery cell 234, or battery cell 236 from temperature sensor 239. As described, temperature sensor 239 may be implemented using various suitable types and configurations of temperature sensors (e.g., using thermistors, thermocouples, RTDs, semiconductors, etc.). Temperature sensor 239 may also be positioned relative to battery cell 232, battery cell 234, and battery cell 236 in various ways depending on the application. Controller 222 may receive temperature data from temperature sensor 239 in various ways (e.g., by detecting a variable resistance, by various suitable communication protocols, etc.). At step 720, process 700 may further include receiving data from additional temperature sensors included in battery 200 (e.g., from temperature sensor 249 and / or from additional temperature sensors included in battery 200).

[0055] At step 730, process 700 may include determining that temperature data associated with the battery cell exceeds a threshold. For example, controller 222 may determine that temperature data received from temperature sensor 239 at step 720 associated with battery cell 232, battery cell 234, or battery cell 236 exceeds a threshold temperature level. The threshold temperature level may be set and / or adjusted based on various factors during operation of battery 200. For example, the threshold temperature level may be a temperature level at which heating of battery cell 232, battery cell 234, or battery cell 236 is no longer required. The threshold temperature level may also vary based on the type of battery cell (e.g., capacity, energy density, voltage range, nominal voltage, weight, etc.) and / or the sampling period used by controller 222 for temperature sensor 239 (e.g., a lower threshold temperature level may be used for a longer sampling period).

[0056] At step 740, process 700 may include: turning on a first switching device to cut off power to the heater of the battery cell. For example, in response to determining at step 730 that temperature data associated with battery cell 232, battery cell 234, or battery cell 236 received from temperature sensor 239 at step 720 exceeds a threshold temperature level, controller 222 may turn on switching device 202 (e.g., by sending a control signal to switching device 202 via various suitable communication protocols) to cut off power to heater 238. Since power for heater 238 may not be routed through switching device 204 in the design of battery 200, controller 222 may turn on switching device 202 at step 740 without turning on switching device 204. After turning on switching device 202 at step 740, controller 222 may adjust the record in memory of the number of times switching device 202 has been turned on (e.g., by incrementing a counter, etc.). Then, controller 222 can (e.g., upon user request, in response to determining that a threshold has been exceeded, etc.) provide an indication of whether switch 202 or switch 204 will wear out faster based on the number of times switch 202 has been turned on and the number of times switch 204 has been turned on (e.g., a higher number of turns indicates a higher probability of faster wear).

[0057] It should be noted that, although in Figure 7 The steps of process 700 are shown in a specific order, but process 700 may not include all the steps shown, may include additional steps, or may include these steps in a different order.

[0058] Although various spatial and directional terms such as top, bottom, lower, middle, lateral, horizontal, vertical, front, etc., may be used to describe examples of this disclosure, it is to be understood that such terms are used only with respect to the orientation shown in the accompanying drawings. The orientation may be reversed, rotated, or otherwise changed such that upper is lower and vice versa, horizontal becomes vertical, etc.

[0059] In this specification, aspects have been described in a manner that enables a clear and concise description; however, it is intended and will be understood that aspects may be combined or separated in various ways without departing from this disclosure. For example, it will be appreciated that all preferred features described herein are applicable to all aspects of the disclosed technology described herein.

[0060] Therefore, although the disclosed technology has been described in conjunction with specific aspects and examples, the disclosed technology is not necessarily limited in this respect, and many other aspects, examples, uses, modifications, and deviations from said aspects, examples, and uses are intended to be covered by the appended claims. The full disclosure of each patent and publication cited herein is incorporated by reference as if each such patent or publication were individually incorporated by reference.

[0061] The various features and advantages of this disclosure are set forth in the appended claims.

Claims

1. A material handling vehicle comprising: a battery compartment; and a battery disposed in the battery compartment, the battery comprising: a battery cell; a heater to provide heat to the battery cell; a temperature sensor to monitor a temperature of the battery cell; a first switching device through which power for the heater is routed; a second switching device through which power for the heater is not routed; and a controller communicatively coupled to the temperature sensor, the first switching device, and the second switching device, the controller comprising circuitry configured to: receive, from the temperature sensor, temperature data indicative of the temperature of the battery cell; and open the first switching device without opening the second switching device based on the temperature data received from the temperature sensor. The circuitry of the controller is further configured to open the second switching device without opening the first switching device in response to detecting a fault unrelated to the temperature of the battery cell.

2. The material handling vehicle of claim 1, wherein, The circuitry of the controller is further configured to provide an indication of whether the first switching device or the second switching device will wear out faster based on a number of times the first switching device has been opened and a number of times the second switching device has been opened.

3. The material handling vehicle of claim 2, wherein, To open the first switching device based on the temperature data received from the temperature sensor, the circuitry of the controller is configured to determine that the temperature data received from the temperature sensor exceeds a threshold value.

4. The material handling vehicle of claim 1, wherein, The threshold value is dependent on a capacity, an energy density, and a weight of the battery cell.

5. The material handling vehicle of claim 4, wherein, The battery cell comprises a lithium iron phosphate (LFP) battery cell.

6. The material handling vehicle of claim 1, wherein, The battery cell is sealed within a battery housing and disposed in the battery compartment.

7. The material handling vehicle of claim 1, wherein, 8. The material handling vehicle of claim 1, wherein: the battery further comprises a third switching device through which power for the heater is not routed; and the circuitry of the controller is configured to open the first switching device without opening the third switching device based on the temperature data received from the temperature sensor.

9. A battery comprising: a battery cell; a heater to provide heat to the battery cell; a temperature sensor to monitor a temperature of the battery cell; a first switching device through which power for the heater is routed; a second switching device through which power for the heater is not routed; and a controller communicatively coupled to the temperature sensor, the first switching device, and the second switching device, the controller comprising circuitry configured to: receive, from the temperature sensor, temperature data indicative of the temperature of the battery cell; and open the first switching device without opening the second switching device based on the temperature data received from the temperature sensor. ​ ​ 10. The battery of claim 9, wherein, The circuit of the controller is further configured to open the second switching device without opening the first switching device in response to detecting a fault independent of the temperature of the battery cell.

11. The battery of claim 10, wherein, The circuit of the controller is further configured to provide an indication of whether the first switching device or the second switching device will wear out faster based on a number of times the first switching device has been opened and a number of times the second switching device has been opened.

12. The battery of claim 9, wherein, To open the first switching device based on the temperature data received from the temperature sensor, the circuit of the controller is configured to determine that the temperature data received from the temperature sensor exceeds a threshold value.

13. The battery of claim 9, wherein: the battery includes a first resistor connected in series with the first switching device and a second resistor connected in series with the second switching device; the controller is connected to the first resistor and the second resistor to receive a resistance input; and the circuit of the controller is further configured to determine a state of the first switching device and a state of the second switching device based on the resistance input.

14. The battery of claim 9, wherein: the battery includes a shunt to measure current flowing from the battery cell to a load connected to the battery; and the circuit of the controller is further configured to: record a first current measurement associated with the shunt; open or close the heater for a period of time; record a second current measurement associated with the shunt after the period of time has elapsed; and detect a fault associated with the shunt by comparing the first current measurement to the second current measurement.

15. The battery of claim 9, wherein: the battery cell is sealed within a battery housing; and the first switching device, the second switching device, and the controller are disposed on an electronics tray of the battery, the electronics tray disposed above the battery cell and within the battery housing.

16. A battery, comprising: a battery cell; a heater to provide heat to the battery cell; a temperature sensor to monitor a temperature of the battery cell; a first switching device through which power for the heater is routed; a second switching device through which power for the heater is not routed; and a controller communicatively coupled to the temperature sensor, the first switching device, and the second switching device, the controller including a circuit configured to: receive temperature data from the temperature sensor indicative of the temperature of the battery cell; open the first switching device without opening the second switching device based on the temperature data received from the temperature sensor; detect a fault independent of the temperature of the battery cell; and opening the second switching device without opening the first switching device in response to detecting the fault independent of the temperature of the battery cell.

17. The battery of claim 16, wherein, the circuit of the controller is further configured to provide an indication of whether the first switching device or the second switching device will wear out faster based on a number of times the first switching device has been opened and a number of times the second switching device has been opened.

18. The battery of claim 16, wherein, the fault independent of the temperature of the battery cell includes a communication loss fault, a short circuit fault, or a low state of charge condition.

19. The battery of claim 16, wherein, to open the first switching device based on the temperature data received from the temperature sensor, the circuit of the controller is configured to determine that the temperature data received from the temperature sensor exceeds a threshold value.

20. The battery of claim 16, wherein, the battery cell is sealed within a battery housing, and wherein the battery cell includes a lithium iron phosphate (LFP) battery cell.

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