Material handling and other vehicles with functional response to run-time calculations

Abstract

A battery management system (32), a removable battery assembly (30) having an integrated battery management system (32), and a vehicle (100) including said assembly are provided for implementing various runtime calculations disclosed herein. A material handling vehicle (100) is provided, including a drive subsystem (20), a removable battery assembly (30), and vehicle control hardware. The removable battery assembly (30) includes a battery management system (32) programmed to: (i) input or generate a state-of-charge (SOC) signal representing the SOC of the removable battery assembly (30); and (ii) implement a first EWMA signal filter F1 to calculate the current calculation I. C (iii) Implement the second EWMA signal filter F2 to calculate the runtime current I. R The running time current calculation I R Including the current calculation I from the first EWMA signal filter F1 C (iv) Implementing the remaining runtime calculation, such that the vehicle control hardware is programmed to make a functional response to the runtime calculation R. The battery-powered material handling vehicle (100) is programmed to implement a forward-looking remaining runtime calculation R of the on-board battery assembly (30) and make a functional response to the runtime calculation R to produce technical operational effects in the material handling vehicle (100).

Description

Technical Field

[0001] This disclosure relates to material handling and other vehicles, and more particularly, to battery-powered or otherwise battery-powered material handling vehicles, such as, for example, pallet trucks, forklifts, reach trucks, rotary forklifts, stackers, pedestrian stackers, tractors, trailer loaders, side loaders, forklift cranes, or any other type of material handling vehicle that derives at least some of its operating power from rechargeable batteries. This disclosure also relates more broadly to vehicles. Summary of the Invention

[0002] While measuring the state of charge (SOC) of a battery can provide useful information about the condition of the rechargeable battery powering a material handling vehicle, the inventors have recognized that there are specific limitations to over-reliance on battery SOC when operating a material handling vehicle. For example, the state of health (SOH) of a battery typically decreases with repeated charge / discharge cycles. Even when both batteries have a SOC of 100%, this results in a difference in the actual energy content (i.e., capacity) of a "cycled" battery compared to a "fresh" battery.

[0003] In many cases, battery-powered material handling vehicles can be configured to receive batteries with different charging capacities. For example, a given vehicle operating with power from a low-capacity battery at 75% SOC cannot operate for as long as a high-capacity battery operating at 75% SOC. Furthermore, material handling fleets often include various vehicles with different power requirements. If these vehicles share a common rechargeable battery source—that is, if batteries can be exchanged between different vehicles with different power requirements—then the SOC indication of a specific battery becomes even less useful to the vehicle operator. Accordingly, the inventors have recognized that in many cases, the SOC indication alone is insufficient to convey the useful remaining charge of the battery to the operator of a battery-powered material handling vehicle.

[0004] According to the subject matter of this disclosure, battery-powered material handling vehicles are programmed to perform forward-looking remaining runtime calculations R of the onboard battery and to make functional responses to the runtime calculations R to produce technical operational effects within the material handling vehicle. The runtime calculations proposed in this paper are based on a learning algorithm that generates runtime calculation representations that do not suddenly and drastically decrease with decreasing battery SOC; that is, the runtime calculations proposed in this paper are more predictable and linear than conventional SOC and runtime calculations. Furthermore, the runtime calculations proposed in this paper are more accurate than conventional battery evaluation schemes because they are based on algorithms that take into account the unique characteristics of each battery and, for example, on the current and voltage characteristics observed for each battery.

[0005] The method of calculating the remaining battery runtime and making a functional response to the runtime R is also anticipated and is widely applicable to material handling vehicles that utilize fully charged or partially discharged batteries.

[0006] More specifically, the remaining runtime calculation R used to generate the functional response and technical effect described herein includes a historical component and a contemporary component, and therefore, the runtime calculation R gradually becomes more accurate over time as it adapts to the specific duty cycle of the vehicle in which the rechargeable battery is used. It is noteworthy that the battery management system of this disclosure is programmed to perform the remaining runtime calculation by implementing a first EWMA signal filter as a pre-filter for a second EWMA signal filter. The abbreviation EWMA stands for Exponentially Weighted Moving Average, a quantitative or statistical measure used to model or describe time series for technical analysis. The abbreviation EMA, often used interchangeably with EWMA, more generally refers to an Exponentially Weighted Moving Average, which may or may not include weighting factors.

[0007] While the concepts of this disclosure are described herein primarily with reference to battery-powered pallet trucks with removable battery components, these concepts are contemplated to apply to any material handling vehicle at least partially powered by a rechargeable battery, regardless of whether the battery is removable. The contemplated vehicles may also include supplemental or alternative power sources, including any conventional or yet-to-be-developed power sources suitable for material handling vehicles. The material handling vehicles contemplated in this disclosure can be configured for operation within or outside a warehouse environment. In the context of this disclosure, it should be noted that a “warehouse environment” encompasses any indoor or outdoor industrial facility in which material handling vehicles transport goods, including, but not limited to, indoor or outdoor industrial facilities primarily used for the storage of goods (such as facilities with multi-level shelving arranged in aisles), and manufacturing facilities in which goods are transported by material handling vehicles around the facility for use in one or more manufacturing processes. Outside of a warehouse environment, the material handling vehicles contemplated in this disclosure include any vehicle primarily configured for the transport of goods, such as, for example, a material handling vehicle designed to operate in a storage space of a vehicle on a road.

[0008] According to one embodiment of this disclosure, a material handling vehicle is provided, comprising a material handling subsystem, a drive subsystem, a removable battery assembly, and vehicle control hardware. The vehicle control hardware may be dedicated to the material handling subsystem, the drive subsystem, or the removable battery assembly, or may be shared by a combination thereof. The material handling subsystem, the drive subsystem, and the vehicle control hardware are configured to cooperate under power from the removable battery assembly to perform multiple pick-up / placement operations, wherein the pick-up / placement operations are characterized by a minimum duration. The removable battery assembly includes a battery management system programmed to input or generate a state-of-charge (SOC) signal representing the battery assembly's state of charge (SOC); and to implement a first EWMA signal filter F1 to calculate the current I. C sequence ( ), where the current calculation is performed in increments of time interval t1 and includes:

[0009]

[0010] Where A includes the average current load on the battery within time interval t1, and B includes the predetermined current load or historical EWMA current calculations that are earlier in time than the average current load A. Including the first weighted parameter, and .

[0011] The battery management system is also programmed to implement a second EWMA signal filter F2 to calculate the runtime current I. R The calculation of running time current includes:

[0012]

[0013] Where C includes the current calculation I from the first EWMA signal filter F1. C Multiple sequences ( In the time envelope t E The average value within the range, D includes the current calculation I that is earlier in time than the current from the first EWMA signal filter F1. C Multiple sequences ( Historical EWMA current calculations for at least one sequence in ) Including the second weighted parameter.

[0014] The battery management system is also programmed to calculate the remaining runtime R, which includes:

[0015]

[0016] Furthermore, the vehicle control hardware is programmed to provide a functional response to the runtime calculation R.

[0017] According to the intermediate-range embodiments, the material handling vehicle of this disclosure is expected to include various combinations of the material handling subsystem, drive subsystem, removable battery assembly and vehicle control hardware mentioned above.

[0018] Further embodiments of this disclosure may include a battery management system programmed to perform various combinations of the implementation steps described above, and various combinations of the aspects of each implementation step mentioned above. For example, the battery management system of this disclosure may be programmed to: (i) input or generate a state-of-charge (SOC) signal representing the SOC of a battery assembly; and (ii) implement a first EWMA signal filter F1 to calculate the current current I. C sequence ( (iii) Implement the second EWMA signal filter F2 to calculate the runtime current I. R The running time current calculation I R Including the current calculation I from the first EWMA signal filter F1 C ; and (iv) implement the calculation of the remaining running time R, which includes:

[0019]

[0020] The vehicle control hardware is programmed to provide a functional response to the runtime calculation R.

[0021] More fully, according to another embodiment of this disclosure, a vehicle is provided, the vehicle including a drive subsystem, a removable battery assembly, and vehicle control hardware. The vehicle control hardware may be dedicated to either the drive subsystem or the removable battery assembly, or may be shared by a combination thereof. The removable battery assembly includes a battery management system programmed to: (i) input or generate a state-of-charge (SOC) signal representing the SOC of the battery assembly; and (ii) implement a first EWMA signal filter F1 to calculate the current I. C sequence ( (iii) Implement the second EWMA signal filter F2 to calculate the runtime current I. R The running time current calculation I R Including the current calculation I from the first EWMA signal filter F1 C ; and (iv) implement the calculation of the remaining running time R, which includes:

[0022]

[0023] The vehicle control hardware is programmed to provide a functional response to the runtime calculation R.

[0024] According to a first aspect of the above-mentioned embodiments, the vehicle includes a material handling subsystem and vehicle control hardware is either dedicated to the material handling subsystem, the drive subsystem, or the removable battery assembly, or shared by a combination thereof, and the material handling subsystem, the drive subsystem, and the vehicle control hardware are configured to cooperate under power from the removable battery assembly to perform multiple pick-up / place-down operations.

[0025] According to the second aspect of the above-mentioned embodiments, the second aspect may be selectively combined with any previously or subsequently disclosed embodiments, aspects, features and characteristics of this disclosure, wherein the first EWMA signal filter F1 includes historical EWMA components and the second EWMA signal filter F2 includes historical EWMA components.

[0026] According to additional embodiments of this disclosure, a removable battery assembly and an integrated battery management system are provided for implementing various runtime calculations disclosed herein.

[0027] According to alternative embodiments of this disclosure, an integrated battery management system is provided for implementing various runtime calculations disclosed herein.

[0028] Various aspects of this disclosure will apply to any previously and subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure. Specifically, according to a first aspect of this disclosure, which can be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure, the vehicle control hardware of the material handling subsystem includes a user interface lift / lower control device and supporting electronics, and the user interface lift / lower control device and supporting electronics are configured to automatically disconnect, gradually limit, or otherwise disable the lift / lower function of the material handling vehicle when R is calculated based on the running time, or when the running time calculated as R drops below a predetermined threshold.

[0029] According to a second aspect of this disclosure, which can be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure, the vehicle control hardware of the material handling subsystem includes a user interface drive mode control device and supporting electronics, and the user interface drive mode control device and supporting electronics are configured to automatically cut off, gradually limit, or otherwise disable a specific drive mode of the material handling vehicle when R is calculated based on the running time, or when the running time calculated as R drops below a predetermined threshold.

[0030] According to a third aspect of this disclosure, which can be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure, the vehicle control hardware of the material handling subsystem includes battery hardware and supporting electronics, and the battery hardware and supporting electronics include battery insertion / removal hardware, diagnostic controls, or a visual display on the battery assembly, and are configured to calculate R based on runtime, or to automatically change, enable, or disable R when the calculated runtime drops below a predetermined threshold. Optionally, the battery hardware and supporting electronics may include a visual runtime display on the battery or at other locations on the vehicle, which is configured to gradually change based on the calculated runtime R. According to a feature of the aforementioned aspect, which can be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure, the runtime display includes a non-numerical graphical representation of the remaining runtime using increments representing equal amounts of time, to avoid situations where some increments in the graphical representation disappear faster than others as the remaining runtime decreases.

[0031] According to a fourth aspect of this disclosure, which can be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure, the battery management system is programmed to reduce the time envelope t of the second EWMA signal filter F2 according to the SOC of the battery assembly. E .

[0032] According to a first feature of the first aspect of this disclosure, which can be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure, the battery management system is programmed to reduce the time envelope t of the second EWMA signal filter F2 when the SOC of the battery assembly drops below a first SOC threshold. E The battery management system can be programmed to further reduce the time envelope t of the second EWMA signal filter F2 when the state of charge (SOC) of the battery component drops below a second SOC threshold that is lower than a first SOC threshold. E .

[0033] According to a second feature of the first aspect of this disclosure, this second feature can be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure, in which the time envelope t of the second EWMA signal filter F2... E It is a multiple of the time interval t1, and it regresses from a first multiple when the SOC of the battery module is above the first SOC threshold to a lower second multiple when the SOC of the battery module drops below the first SOC threshold.

[0034] According to the first feature of the second feature of the first aspect of the present disclosure, the first feature may be selectively combined with previously or subsequently disclosed embodiments, aspects, features and characteristics of the present disclosure, and the first SOC threshold may be between approximately 10% and approximately 30%.

[0035] According to a second feature of the second feature of the first aspect of this disclosure, this second feature can be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure, when the SOC of the battery assembly is higher than a first SOC threshold, the time envelope t of the second EWMA signal filter F2 E The time envelope t of the second EWMA signal filter F2 is approximately 3 minutes and the time interval t1 is approximately 1 minute. When the SOC of the battery module drops below the first SOC threshold, the time envelope t1 is approximately 3 minutes. E Approximately 2 minutes.

[0036] According to a third feature of the second feature of the first aspect of this disclosure, the third feature can be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure, such that when the SOC of the battery assembly drops below a second SOC threshold, the time envelope t of the second EWMA signal filter F2... E Further regression from the second lower multiple to the third lower multiple.

[0037] According to the first variation of the third feature mentioned above, this first variation can be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure, and the second SOC threshold can be between approximately 5% and approximately 20%. According to the second variation, this second variation can be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure, and when the SOC of the battery assembly drops below the second SOC threshold, the time envelope t of the second EWMA signal filter F2... E Approximately 1 minute.

[0038] According to the fifth and sixth aspects of this disclosure, this feature can be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure. or .

[0039] According to the seventh aspect of this disclosure, which may be selectively combined with previously or subsequently disclosed embodiments, aspects, features and characteristics of this disclosure, the average current load A of the first EWMA signal filter F1 is determined based on hundreds of current value readings within a time interval t1, and the time interval t1 is between approximately 1 minute and approximately 10 minutes.

[0040] According to the eighth aspect of this disclosure, which may be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure, the battery management system is programmed to implement a first EWMA signal filter F1, wherein B includes historical EWMA current calculations obtained before the material handling vehicle enters an atypical operating mode.

[0041] According to a ninth aspect of this disclosure, which can be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure, the battery management system is programmed to implement a first EWMA signal filter F1 when historical EWMA current calculation is unavailable, wherein B includes a predetermined current load, and ,in This includes the maximum current load on the battery assembly, where the material handling subsystem, drive subsystem, and vehicle control hardware are configured to cooperate in performing multiple pick-and-place operations.

[0042] According to the tenth aspect of this disclosure, which may be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure, the battery management system is programmed to implement a first EWMA signal filter F1, wherein B includes historical EWMA current calculations as the average of the EWMA of the average current load A and one or more previously calculated battery component current loads.

[0043] According to the eleventh aspect of this disclosure, which may be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure, the battery management system is programmed to calculate successive operating time currents IR1, IR2, IR3, etc. by advancing sampling periods associated with the historical EWMA current calculation D of the average value C and the second EWMA signal filter F2 over time.

[0044] According to the twelfth aspect of this disclosure, which may be selectively combined with previously or subsequently disclosed embodiments, aspects, features and characteristics of this disclosure, in order to calculate successive operating time currents IR1, IR2, IR3, etc., the sampling periods associated with the historical EWMA current calculation D of the average value C and the second EWMA signal filter F2 are all advanced by time interval t1.

[0045] According to the thirteenth aspect of this disclosure, which may be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure, the battery management system is programmed to: (i) implement a first EWMA signal filter F1, wherein B includes historical EWMA current calculation, which is the average value of the EWMA of the average current load A and one or more previously calculated battery module current loads; (ii) calculate successive operating time currents IR1, IR2, IR3, etc. by advancing sampling periods associated with the average value C and the historical EWMA current calculation D of the second EWMA signal filter F2 in time; and (iii) in order to calculate the successive operating time currents IR1, IR2, IR3, etc., the sampling periods associated with the average value C and the historical EWMA current calculation D of the second EWMA signal filter F2 are all advanced by time interval t1.

[0046] According to the fourteenth aspect of this disclosure, which may be selectively combined with previously or subsequently disclosed embodiments, aspects, features and characteristics of this disclosure, the material handling subsystem, drive subsystem and vehicle control hardware are configured to cooperate in performing multiple pick-up / place-down operations, such that the actual current load I on the battery assembly cycles between local maximum and local minimum values ​​multiple times within a time interval t1.

[0047] According to a first feature of the fourteenth aspect of this disclosure, the first feature may be selectively combined with previously or subsequently disclosed embodiments, aspects, features and characteristics of this disclosure, wherein the local maximum value differs from the local minimum value by at least approximately 1000 mA and the time interval t1 is approximately 1 minute.

[0048] According to the second feature of the fourteenth aspect of this disclosure, the second feature may be selectively combined with previously or subsequently disclosed embodiments, aspects, features and characteristics of this disclosure, wherein the local maximum value and the local minimum value differ by at least approximately 1000 mA and the time interval t1 ≤ 1 minute.

[0049] According to the first feature of the second feature of the fourteenth aspect of this disclosure mentioned above, the first feature can be selectively combined with previously or subsequently disclosed embodiments, aspects, features and characteristics of this disclosure, and the local maximum and local minimum values ​​are both greater than 0 mA.

[0050] According to the second feature of the fourteenth aspect of this disclosure mentioned above, the second feature may be selectively combined with previously or subsequently disclosed embodiments, aspects, features and characteristics of this disclosure, with a local maximum value greater than zero amperes and a local minimum value less than or equal to 0 mA.

[0051] According to the first variation of the features mentioned above, the first variation may be selectively combined with previously or subsequently disclosed embodiments, aspects, features and characteristics of this disclosure, wherein the local maximum value differs from the local minimum value by at least approximately 1000 mA and less than approximately 5000 mA.

[0052] According to the fifteenth aspect of this disclosure, this fifteenth aspect may be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure, (i) a material handling subsystem, a drive subsystem, and vehicle control hardware configured to cooperate in performing multiple pick-up / place-down operations such that the actual current load I on the battery assembly varies multiple times within a time interval t1 by at least approximately 1000 mA and less than approximately 5000 mA. (ii) The battery management system is programmed to implement a first EWMA signal filter F1, wherein B includes historical EWMA current calculations as the average of the EWMA of the average current load A and one or more previously calculated battery module current loads; (iii) The battery management system is programmed to calculate successive operating time currents IR1, IR2, IR3, etc. by advancing sampling periods associated with the average C and the historical EWMA current calculations D of the second EWMA signal filter F2 over time; (iv) In order to calculate successive operating time currents IR1, IR2, IR3, etc., the sampling periods associated with the average C and the historical EWMA current calculations D of the second EWMA signal filter F2 are all advanced by time interval t1; and (v) .

[0053] According to a further embodiment of this disclosure, a method for calculating the remaining battery runtime of a removable material handling vehicle battery assembly is provided, the method utilizing the material handling vehicle, removable battery assembly, and / or battery management system disclosed herein.

[0054] According to one aspect of the various methods contemplated herein, which may be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure, the vehicle control hardware of the material handling subsystem includes a user interface lift / lower control device and supporting electronics, and the method includes using the lift / lower control device and supporting electronics to calculate R based on the running time, or automatically cutting off, gradually limiting, or otherwise disabling the lift / lower function of the material handling vehicle when the calculated R drops below a predetermined threshold.

[0055] Additional aspects of the various methods contemplated herein, which may be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure, include vehicle control hardware for the material handling subsystem comprising a user interface drive mode control device and supporting electronics, and the method further includes using the drive mode control device and supporting electronics to calculate R based on runtime, or automatically cutting off, gradually limiting, or otherwise disabling a specific drive mode of the material handling vehicle when the runtime-calculated R drops below a predetermined threshold.

[0056] Further aspects of the various methods contemplated herein may be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of the present disclosure, wherein the vehicle control hardware of the material handling subsystem includes battery hardware and supporting electronics, and the method further includes calculating R based on runtime, or automatically changing, enabling, or disabling the battery hardware and supporting electronics when the runtime-calculated R drops below a predetermined threshold.

[0057] According to the features of the above-mentioned aspects of this disclosure, these features can be selectively combined with previously or subsequently disclosed embodiments, aspects, features, and characteristics of this disclosure, the battery hardware and supporting electronics include a visual runtime display located on the battery or in other locations on the vehicle, and the method further includes progressively changing the runtime indication on the visual runtime display based on a runtime calculation R. Attached Figure Description

[0058] The following detailed description of specific embodiments of this disclosure will be understood when read in conjunction with the following accompanying drawings, wherein similar structures are indicated by similar reference numerals and wherein:

[0059] Figure 1 This is an illustration of a material handling vehicle (i.e., a pallet truck), which includes vehicle control hardware and a battery assembly that may be removable.

[0060] Figure 2 It is a schematic diagram of a material handling vehicle that includes battery components, a battery management system, a battery connector assembly, a material handling subsystem, and a drive subsystem.

[0061] Figure 3 The diagram illustrates the actual current load I, state of charge (SOC), and calculated operating time current I of the battery pack of the material handling vehicle according to this disclosure. R A graph showing the time progress of the runtime R;

[0062] Figure 4 An example of an embodiment of the first EWMA signal filter F1 according to this disclosure is illustrated; and

[0063] Figure 5-7The figure illustrates a time envelope t with progressively shortening according to the present disclosure. E An example of an implementation of the second EWMA signal filter F2. Detailed Implementation

[0064] First refer to Figure 1 and Figure 2 The illustration shows a material handling vehicle 100 according to the present disclosure, which includes a material handling subsystem 10, a drive subsystem 20, a removable battery assembly 30, vehicle control hardware such as a user interface lift / lower control device 12 and a user interface drive mode control device 22, and battery hardware such as battery insertion / removal hardware, a diagnostic control device associated with the battery assembly 30, or a visual display 36 on the battery assembly 30. The removable battery assembly 30 may also include a releasable mating connector assembly 40, wherein a battery-side connector assembly 42 and a vehicle-side connector assembly 44 are releasably engaged. The battery-side connector assembly 42 and the vehicle-side connector assembly 44 may be configured to electrically couple the removable battery assembly to the material handling subsystem 10, the drive subsystem 20, and the vehicle control hardware of the material handling vehicle 100.

[0065] The user interface lifting / lowering control device 12 and the necessary supporting electronics mentioned above can include any conventional or yet-to-be-developed lifting / lowering control device, such as a toggle switch or joystick on the handle of a pallet truck, or a lifting / lowering joystick in the operator's cab of a forklift. These control devices and their supporting electronics can be entirely located at the material handling vehicle, can functionally communicate with the material handling vehicle but not located at the material handling vehicle, or can include components located at the material handling vehicle and components that only communicate with the material handling vehicle but are not located at the vehicle, as in the case of remote control devices or server-based control devices. More simply, the user interface lifting / lowering control device 12 can be entirely located on the vehicle 100, can be located remotely from the vehicle 100, or can be a combination thereof.

[0066] Similarly, the user interface drive mode control device 22 and the necessary supporting electronics mentioned above may include any conventional or yet-to-be-developed drive mode control device, such as a forward / reverse toggle switch or joystick on the handle of a pallet truck, drive mode buttons and joysticks in the operator's cab of a forklift, etc. As described above with reference to the lift / lower control device 12 and supporting electronics, these drive mode control devices 22 and their supporting electronics may be located entirely on the vehicle 100, remote from the vehicle 100, or a combination thereof.

[0067] As those familiar with material handling vehicles, especially battery-powered or otherwise battery-powered material handling vehicles, will recognize, the vehicle control hardware mentioned above may be dedicated to the material handling subsystem 10, drive subsystem 20, or removable battery assembly 30, or may be shared by a combination of them.

[0068] The material handling subsystem 10, drive subsystem 20, and vehicle control hardware are configured to cooperate under power from the removable battery assembly 30 to perform multiple pick / place operations. As those familiar with material handling operations and material handling vehicles will recognize, a pick / place operation refers to the process of moving materials from one location to another using the material handling subsystem, drive subsystem, and vehicle control hardware of a material handling vehicle (e.g., a forklift, pallet truck, etc.). This can include picking up a load from a pallet or storage rack, transporting it to a new location, and placing it on another pallet or storage rack. More specifically, typical pick / place operations may include:

[0069] • Pre-operation checks: Before operating the lifting truck, the operator can perform a visual inspection to ensure all safety devices and equipment are in place and functioning properly. The operator can also check the battery level and other truck parameters against the truck's pre-operation checklist.

[0070] • Positioning the Lift Truck: The operator positions the lift truck so that the forks or other material handling hardware are aligned with the load and the load can be safely lifted and transported. This may require the operator to use the vehicle's control hardware to adjust the position of the lift truck.

[0071] • Lifting the load: The operator interfaces with the vehicle's control hardware to raise the forks or other material handling hardware to the appropriate height and engage the load. Before moving the load, it should be securely engaged and the stability of the lifting truck should be checked.

[0072] • Transporting loads: The operator uses the control hardware on the vehicle to move the vehicle and load to the desired location.

[0073] • Load Placement: The operator uses the vehicle's control hardware to lower the load and place it onto the desired pallet, storage rack, or other surface to check for a secure and stable fit with the surface.

[0074] These pick / place operations can be defined by a minimum duration. To characterize. Each pick / place operation will typically have a minimum duration on the order of a few seconds. More complex pick-up / place-down operations can be completed in a matter of minutes.

[0075] The removable battery assembly 30 may include a battery management system 32, which may be programmed to input or generate a state-of-charge (SOC) signal representing the SOC of the battery assembly and to implement first and second EWMA signal filters F1, F2 and a remaining runtime calculation R, allowing the vehicle 100 to functionally respond to the runtime calculation R. The SOC signal may be input or generated by the battery management system in a variety of ways. For example, it may be calculated or estimated by the battery management system (BMS) or another component of the material handling vehicle communicating with the BMS, determined according to a model, or input from an external source based on the aforementioned conventional and pending teachings on SOC estimation. This disclosure is not directed toward SOC estimation techniques, as existing and pending literature provides abundant teachings on the subject. Rather, this disclosure uses SOC as an input in an architecture that provides an indication of battery runtime in a battery-powered material handling vehicle.

[0076] More specifically, the first EWMA signal filter F1 is implemented to achieve a time envelope t E Calculate the current I above C sequence ( These current calculations are performed in increments of time interval t1 and include:

[0077]

[0078] Where A includes the average current load on the battery within time interval t1, and B includes the predetermined current load or historical EWMA current calculations that are earlier in time than the average current load A. Including the first weighted parameter, and . Figure 4 An example implementation of the first EWMA signal filter F1 is illustrated, where t1 is one minute, A is the average current load on the battery in the previous minute, and B is either the most recent EWMA current calculation of the battery or an ampere value representing the typical average current drawn by the vehicle battery, for example, 5 amperes, if the battery is a "native" battery, i.e., if no EWMA current has been calculated for the battery before.

[0079] When a battery-powered material handling vehicle enters an atypical operating mode, such as when entering the “creep” mode described below, care should be taken to ensure that the most recent EWMA current calculation (i.e., the “last EMA value”) of the battery was obtained before the vehicle entered the atypical operating mode. By doing so, the integrity of the first EWMA signal filter F1 and the subsequent runtime calculation R is protected from the current draw characteristics of the atypical operating mode, which is important because atypical operating modes (such as the “creep” or “lift lockout” modes described below) do not represent the typical duty cycle of the material handling vehicle.

[0080] Referring more specifically to the first EWMA signal filter F1, it should be noted that the average current load A of the first EWMA signal filter F1 can be determined based on thousands of current value readings within the time interval t1. For example, and not limited to, the average current load A of the first EWMA signal filter F1 can be determined by reading the current value every 50 milliseconds within a 1-minute time period, which would produce 1200 current readings per minute. Given the variability associated with battery-powered material handling vehicles operating inside and outside warehouse environments, it is anticipated that setting the time interval t1 to a value between approximately 1 minute and approximately 10 minutes may be preferred in many cases.

[0081] Figure 3 The diagram shows the actual current load I, state of charge (SOC), and calculated runtime current I of the removable battery module of a material handling vehicle performing multiple pick-and-place operations. R A graph showing the time progress of the runtime R. For example... Figure 3 As shown, the material handling subsystem 10, drive subsystem 20, and vehicle control hardware are configured to cooperate in performing multiple pick-up / place-down operations, causing the actual current load I on the battery assembly 30 to cycle volatilely between local maxima and local minima multiple times within the aforementioned time interval t1. Within a given time interval t1, for example, approximately 1 minute, many local maxima differ from minimums by at least approximately 1000 mA. Other local maxima and minimums within a given time interval t1 remain above 0 mA. Further local maxima and minimums within a given time interval t1 extend above and below 0 mA, while further local maxima and minimums within a given time interval t1 differ by at least approximately 1000 mA and up to approximately 5000 mA. Further local maxima and minimums within a given time interval t1 differ by up to 30-50 A, while other material handling vehicles can generate power swings on the order of hundreds of amperes.

[0082] like Figure 4As shown, the battery management system 32 can be programmed to implement a first EWMA signal filter F1, where B includes available historical EWMA current calculations. The historical EWMA current calculations can be introduced as the average of the EWMA of the average current load A and one or more previously calculated battery module current loads. In some cases, historical EWMA current calculations will not be available when the first EWMA signal filter F1 is implemented. To address this issue, the battery management system 32 can be programmed to implement the first EWMA signal filter F1, where B instead includes a predetermined current load, as shown below:

[0083]

[0084] in Including the maximum current load (Amperes) on battery assembly 30, where the material handling subsystem 10, drive subsystem 20, and the aforementioned vehicle control hardware are configured to cooperate in performing multiple pick-up / place-down operations, note The value depends on the specific material handling vehicle used, and can be approximated as 30 amps for many vehicles, for example.

[0085] Implement the second EWMA signal filter F2 to calculate the runtime current I. R This current can be used to calculate R based on the running time using the following formula:

[0086]

[0087] In battery-powered material handling vehicles, the State of Charge (SOC) of a battery cell can be defined as the battery's available capacity, often expressed as ampere-hours (Ah), and can be expressed as a percentage of its rated capacity. Additional details regarding SOC determination are given below.

[0088] like Figure 5 As shown, the runtime current calculation facilitated by the second EWMA signal filter F2 includes:

[0089]

[0090] Where C includes the current calculation I from the first EWMA signal filter F1. C Multiple sequences ( In the time envelope t E The average value within the range, D includes the current calculation I that is earlier in time than the current from the first EWMA signal filter F1. C Multiple sequences ( Historical EWMA current calculations for at least one sequence in ) Including the second weighted parameter, where Often smaller than And constitutes the calculation of the current I. C Time envelope t E The time interval t1 is greater than the minimum duration of the pick / place operation performed by the material handling vehicle. .

[0091] Figure 5 An example implementation of the second EWMA signal filter F2 is illustrated, wherein the time envelope t E It is three minutes, and C is the current calculated from the first three currents of the first EWMA signal filter F1. C The average value obtained within the envelope of the first three minutes, and D is calculated earlier than these three currents. C The last two in the calculation of historical EWMA current.

[0092] like Figure 5 As shown, the battery management system 32 can be programmed to calculate successive runtime currents IR1, IR2, …, IR3 by advancing the sampling periods associated with the historical EWMA current calculation D of the average value C and the second EWMA signal filter F2 over time. n The sampling periods associated with the historical EWMA current calculation D, which is related to the average value C and the second EWMA signal filter F2, can be advanced by time interval t1 to calculate the successive running time currents IR1, IR2, …, IR. n wait.

[0093] like Figure 4 and Figure 5 As shown, the first and second EWMA signal filters F1 and F2 utilize weighting parameters and The first EWMA signal filter F1 Greater than the second EWMA signal filter F2 More specifically, it is expected that in many material handling applications, if

[0094] ,

[0095] Therefore, runtime calculations will be particularly informative and functional. For example, refer to... Figure 3 In a battery-powered or otherwise battery-powered material handling vehicle in a specific material handling environment, the current load over time t (min) will include the following components, wherein:

[0096] • The vehicle is not moving or carrying a load, and the current load on the battery is close to zero (see, for example, t < 2 minutes).

[0097] • The vehicle performs various pick-up / place-down operations, has various material loads, and travels up and down slopes (see, for example, 2 minutes < t < 25 minutes) or on flat ground (see, for example, 28 minutes < t < 72 minutes).

[0098] • The vehicle only performs raising / lowering operations and does not move (see, for example, 25 minutes < t < 28 minutes); and

[0099] • The vehicle travels at a crawl speed (e.g., 1.5 km / hr), which can be used when the remaining run time calculation R returns a value of less than 5-10 minutes (see, for example, 72 minutes < t < 80 minutes).

[0100] In the context of the above example, and not as a limitation, the variability of the current load mentioned above in runtime calculations can be addressed by... and This can be addressed by setting it between 0 and 1. Alternatively, more specifically, in an embodiment, the aforementioned volatility can be mitigated by setting... Set to approximately 0.9 and The solution is to set it to approximately 0.5.

[0101] Figure 6 and Figure 7 The figure illustrates a time envelope t with gradually decreasing time. E The second EWMA signal filter F2 is implemented as follows. More specifically, the battery management system 32 can be programmed to reduce the time envelope t of the second EWMA signal filter F2 according to the SOC of the battery assembly 30. E To enhance the functionality of runtime calculation R. In an embodiment, when the SOC of the battery assembly drops below a first SOC threshold, the time envelope t of the second EWMA signal filter F2... E The time envelope t can be reduced initially, and when the SOC of the battery module drops below a second SOC threshold that is lower than the first SOC threshold, the time envelope t... E It can be reduced a second time. Although the time envelope t of the second EWMA signal filter F2 mentioned above... E Reducing the SOC can lead to more volatile runtime calculations, but the calculations can be more accurate. This trade-off between volatility and accuracy can be particularly advantageous as the SOC of the battery module decreases to lower levels. Furthermore, using multiple SOC thresholds promotes a degree of flexibility in this trade-off, as it allows for greater emphasis on short-term trends in the current profile. In this sense, the algorithm is a fast algorithm that can keep up with rapidly changing battery current profiles to enable more accurate SOC derivation and runtime calculations than conventional runtime calculation methods.

[0102] exist Figure 6 and Figure 7 In the example, the time interval t1 is set to, for example, 1 minute, and the time envelope t of the second EWMA signal filter F2 is... E It is a multiple of the time interval t1, and regresses from a first multiple (e.g., 3 minutes) when the SOC of the battery module is above a first SOC threshold to a lower second multiple (e.g., 2 minutes) when the SOC of the battery module drops below the first SOC threshold, and then regresses to a third lower multiple (e.g., 1 minute) when the SOC of the battery module drops below the second SOC threshold. It is anticipated that the first SOC threshold can be set between approximately 10% and approximately 30%, and the second SOC threshold can be set between approximately 5% and approximately 20%. For example, and not as a limitation, the first SOC threshold can be approximated as 20% and the second SOC threshold can be approximated as 10%. This is achieved by using the time envelope t of the second EWMA signal filter F2. E Set to a multiple of the time interval t1, which can be aligned in time with the various components of the second EWMA signal filter F2, allowing for more accurate runtime calculations.

[0103] Vehicle control hardware can be programmed to functionally respond to runtime calculations R to produce technical operational effects in material handling vehicles. More specifically, for the purpose of further illustrating the subject matter of this disclosure and not limiting it, runtime calculations can be used to control hardware on the battery, such as battery insertion / removal hardware, diagnostic controls, or battery displays, as the runtime calculations reach various decreasing values ​​from the initially calculated runtime.

[0104] For example, and not as a limitation, the user interface lift / lower control device 12 and supporting electronics of the material handling vehicle 100 can be configured to automatically enter a "lift-lock" mode, wherein the lift / lower function of the material handling vehicle 100 is cut off, gradually restricted, or otherwise disabled based on a calculated operating time R, or when the calculated operating time R drops below a predetermined threshold. For example, to further illustrate the subject matter of this disclosure and not as a limitation, when the calculated operating time drops below 5-10 minutes, the material handling mechanism can be set to a safe driving height while disabling all other lift / lower functions so that the vehicle can drive directly to a battery recharging station or battery swapping station, either manually or automatically. Alternatively, when the operating time is below 5-10 minutes, the lift / lower button on the pallet truck's handle can be disabled if the material handling mechanism is in an appropriate state.

[0105] As a further example, the user interface drive mode control device 22 and supporting electronics can be configured to automatically cut off, gradually limit, or otherwise disable a specific drive mode for the material handling vehicle based on the calculated runtime R, or when the calculated runtime R drops below a predetermined threshold. For example, to further illustrate the subject matter of this disclosure and not to limit it, when the calculated runtime drops below 5-10 minutes, the drive subsystem can be set to a relatively slow maximum travel speed, i.e., a “creep mode,” to alert the operator that the available runtime is decreasing.

[0106] As an additional example, battery hardware and supporting electronics (which may be implemented at least in part by BMS 32 or otherwise realize their functionality) may be configured to calculate R based on runtime, or to automatically change, enable, or disable when the calculated runtime R falls below a predetermined threshold. More specifically, the battery hardware may include a visual runtime display 36 on the battery assembly 30 or at other locations on the vehicle, configured to gradually change based on the calculated runtime R, for example, by displaying the remaining runtime in minutes. In embodiments, the calculated runtime is intended to be transmitted at specific time intervals to the display on the battery or at other locations on the vehicle to provide a convenient indication of battery runtime.

[0107] While this disclosure contemplates various conventional or yet-to-be-developed battery modules, the concepts herein are considered particularly useful in the context of a battery module 30 comprising lithium-ion battery cells and more particularly characterized by a maximum battery capacity of approximately 5 AH and approximately 1000 AH or greater, and a weight of approximately 5 kg and approximately 500 kg or greater. In the context of this disclosure, it should be noted that the battery module comprising lithium-ion battery cells utilizes the reversible reduction of lithium ions to store energy.

[0108] The vehicle control hardware mentioned above (e.g., user interfaces, controllers, drive motors, hydraulic or pneumatic lifting / lowering hardware, electronic / electrical hardware, display hardware, and other types of control hardware) is expected to encompass any of a variety of conventional or yet-to-be-developed control hardware that will be incorporated into battery-powered or otherwise battery-powered material handling vehicles to facilitate the operation of the vehicles in their intended manner. For example, and not as a limitation, the battery-powered material handling vehicles according to this disclosure will typically include one or more shared or dedicated battery-side or vehicle-side programmable controllers for performing battery-powered drive, braking, steering, and / or lifting / lowering functions of the vehicle. The vehicle is also intended to incorporate battery-side or vehicle-side user interface control hardware to facilitate vehicle operation. This user interface control hardware may include battery-side or vehicle-side control buttons, switches, user interfaces, displays, lights, audio equipment, etc.

[0109] As stated above, this disclosure is not directed to SOC estimation techniques. However, because the various anticipated runtime calculations R of this disclosure depend on the input or generation of the state of charge signal, for completeness, it should be noted that several methods for measuring the SOC of a battery exist, including:

[0110] • Coulomb counting: This method involves measuring the amount of charge added to or removed from the battery over time. The State of Charge (SOC) is then calculated based on the total charge added or removed relative to the battery capacity.

[0111] • Voltage Measurement: The battery voltage is directly related to its State of Charge (SOC). As the battery discharges, the voltage decreases, and as the battery charges, the voltage increases. By measuring the battery's open-circuit voltage (OCV), it is possible to estimate the SOC.

[0112] • Internal resistance measurement: The internal resistance of a battery is related to its state of charge (SOC). As the battery discharges, the internal resistance increases, and as the battery charges, the internal resistance decreases. By measuring the battery's internal resistance, it is possible to estimate the SOC.

[0113] • Neural Network-Based Approaches: In recent years, neural network-based methods have been developed for estimating the State of Charge (SOC) of a battery. These methods use machine learning algorithms to learn the relationship between the battery's SOC and various input parameters, such as current, voltage, and temperature.

[0114] The accuracy of these methods can vary, and the choice of method will depend on various factors based on subjective system design preferences. Generally, when the battery is unloaded and has been left for a sufficiently long time to allow the battery chemistry to stabilize, it is preferable to use the battery's OCV to determine the SOC. When the battery is under load, coulomb counting is often the preferred method. The battery's OCV can also be used to correct SOC determinations based on coulomb counting methods.

[0115] A battery's state of health (SOH) refers to its overall condition and ability to perform its intended functions. It is typically characterized by factors such as capacity, efficiency, and lifespan. A battery's SOH can affect the accuracy of its state of charge (SOC) measurement in several ways. For example:

[0116] • Capacity loss: As batteries age, their capacity (i.e., the amount of electrical energy they can store) decreases. This can cause batteries to discharge faster than expected, leading to an overestimation of their State of Charge (SOC).

[0117] • Self-discharge: All batteries have a certain degree of self-discharge, which is the loss of electrical energy caused by internal chemical reactions. The rate of self-discharge increases as the battery ages, which can lead to an underestimation of its state of charge (SOC).

[0118] Accordingly, this disclosure anticipates advantages in taking into account the SOH of the battery to ensure accurate SOC measurement.

[0119] In describing and defining this invention, it should be noted that references herein to a variable being a parameter or a “function” of another variable are not intended to imply that the variable is merely a function of the listed parameter or variable. Rather, references herein to a variable being a “function” of the listed parameter are intended to be open-ended, such that the variable can be a single parameter or a function of multiple parameters.

[0120] It should be noted that descriptions herein of components being "configured" or "programmed" in a particular manner to implement particular characteristics or function in a particular way are structural descriptions, not descriptions of their intended use. More specifically, references herein to the manner in which a component is "configured" or "programmed" indicate the existing physical state of the component and should therefore be regarded as explicit descriptions of the structural characteristics of the component.

[0121] In order to describe and define the present invention, it should be noted that the term "approximate" is used herein to indicate the degree of uncertainty that can be attributed to any quantitative comparison, value, measurement or other representation, and / or the degree to which a quantitative representation may differ from the reference without altering the essential function of the subject matter under discussion.

[0122] Having described the subject matter of this disclosure in detail and with reference to specific embodiments thereof, it should be noted that the various details disclosed herein should not be construed as implying any relation to the essential components of the various embodiments described herein, even where specific elements are illustrated in each of the accompanying drawings. Furthermore, it will be apparent that modifications and variations are possible without departing from the scope of this disclosure, including but not limited to the embodiments defined in the appended claims. More specifically, while some aspects of this disclosure are identified herein as preferred or particularly advantageous, it is not intended that this disclosure be limited to these aspects.

[0123] It should be noted that one or more of the following claims utilize the term "wherein" as a transitional phrase. In defining the invention, it should be noted that this term is introduced in the claims as an open-ended transitional phrase used to introduce a description of a series of features of the structure and should be interpreted in a similar manner to the more commonly used open-ended leading term "comprising."

Claims

1. A material handling vehicle, comprising a material handling subsystem, a drive subsystem, a removable battery assembly, and vehicle control hardware, wherein: The vehicle control hardware may be dedicated to the material handling subsystem, drive subsystem, or removable battery assembly, or a combination thereof. The material handling subsystem, drive subsystem, and vehicle control hardware are configured to cooperate under power from a removable battery module to perform multiple pick-up / placement operations, wherein the pick-up / placement operations are characterized by a minimum duration. ; The removable battery assembly includes a battery management system, which is programmed to: Input or generate a state-of-charge (SOC) signal representing the state of charge (SOC) of the battery assembly. Implement the first EWMA signal filter F1 to calculate the current I. C sequence ( The current calculation is performed in increments of time interval t1 and includes... Furthermore, A includes the average current load on the battery within time interval t1, and B includes a predetermined current load or historical EWMA current calculations that are earlier in time than the average current load A. Including the first weighted parameter, and , Implement the second EWMA signal filter F2 to calculate the runtime current I. R The running time current calculation includes And C includes the current calculation I from the first EWMA signal filter F1. C Multiple sequences ( In the time envelope t E The average value within the range, D includes the current calculation I that is earlier in time than the current from the first EWMA signal filter F1. C Multiple sequences ( Historical EWMA current calculations for at least one sequence in ), and Including the second weighted parameter, and Implement the remaining runtime calculation R, which includes ;as well as The vehicle control hardware is programmed to make functional responses to runtime calculations R.

2. The material handling vehicle as described in claim 1, wherein: The battery management system is programmed to calculate the R output control signal based on runtime; and The vehicle control hardware is programmed to respond functionally to control signals.

3. The material handling vehicle as described in claim 1, wherein: The vehicle control hardware of the material handling subsystem includes a user interface lift / lower control device and supporting electronics, and the user interface lift / lower control device and supporting electronics are configured to automatically cut off, gradually limit, or otherwise disable the lift / lower function of the material handling vehicle based on the calculated R based on the running time, or when the calculated R drops below a predetermined threshold; or The vehicle control hardware of the material handling subsystem includes a user interface drive mode control device and supporting electronics, and the user interface drive mode control device and supporting electronics are configured to automatically cut off, gradually limit or otherwise disable a specific drive mode of the material handling vehicle based on the calculated R based on the running time, or when the calculated R drops below a predetermined threshold.

4. The material handling vehicle as described in claim 1, wherein: The vehicle control hardware for the material handling subsystem includes battery hardware and supporting electronics; and Battery hardware and supporting electronics include battery insertion / removal hardware, diagnostic controls, or visual displays on the battery assembly, and are configured to calculate R based on runtime, or to automatically change, enable, or disable R when the runtime-calculated R drops below a predetermined threshold.

5. The material handling vehicle of claim 4, wherein the battery hardware and supporting electronics include a visual runtime display on the battery or at other locations on the vehicle, the display being configured to gradually change based on a runtime calculated as R.

6. The material handling vehicle of claim 1, wherein the battery management system is programmed to decrease the time envelope t of the second EWMA signal filter F2 according to the SOC of the battery assembly. E .

7. The material handling vehicle of claim 6, wherein the battery management system is programmed to reduce the time envelope t of the second EWMA signal filter F2 when the SOC of the battery assembly drops below a first SOC threshold. E .

8. The material handling vehicle of claim 7, wherein the battery management system is programmed to further reduce the time envelope t of the second EWMA signal filter F2 when the SOC of the battery assembly drops below a second SOC threshold lower than a first SOC threshold. E .

9. The material handling vehicle as described in claim 6, wherein the time envelope t of the second EWMA signal filter F2 E It is a multiple of the time interval t1, and it regresses from the first multiple when the SOC of the battery module is above the first SOC threshold to a lower second multiple when the SOC of the battery module drops below the first SOC threshold.

10. The material handling vehicle of claim 9, wherein the first SOC threshold is between approximately 10% and approximately 30%.

11. The material handling vehicle as claimed in claim 9, wherein: When the SOC of the battery module is higher than the first SOC threshold, the time envelope t of the second EWMA signal filter F2 E Approximately 3 minutes and the time interval t1 is approximately 1 minute; and When the SOC of the battery assembly drops below the first SOC threshold, the time envelope t of the second EWMA signal filter F2... E Approximately 2 minutes.

12. The material handling vehicle of claim 9, wherein when the SOC of the battery assembly drops below the second SOC threshold, the time envelope t of the second EWMA signal filter F2... E Further regression from the second lower multiple to the third lower multiple.

13. The material handling vehicle of claim 12, wherein the second SOC threshold is between approximately 5% and approximately 20%.

14. The material handling vehicle of claim 12, wherein when the SOC of the battery assembly drops below a second SOC threshold, the time envelope t of the second EWMA signal filter F2... E Approximately 1 minute.

15. The material handling vehicle as described in claim 1, wherein: 。 16. The material handling vehicle as claimed in claim 1, wherein: 。 17. The material handling vehicle as claimed in claim 1, wherein: The average current load A of the first EWMA signal filter F1 is determined based on hundreds of current readings within time interval t1; and The time interval t1 is between approximately 1 minute and approximately 10 minutes.

18. The material handling vehicle of claim 1, wherein the battery management system is programmed to implement a first EWMA signal filter F1, wherein B includes historical EWMA current calculations obtained before the material handling vehicle enters an atypical operating mode.

19. The material handling vehicle as claimed in claim 1, wherein: The battery management system is programmed to implement a first EWMA signal filter F1 when historical EWMA current calculation is unavailable, where B includes a predetermined current load, and in This includes the maximum current load on the battery assembly, wherein the material handling subsystem, drive subsystem, and vehicle control hardware are configured to cooperate in performing the multiple pick-and-place operations.

20. The material handling vehicle of claim 1, wherein the battery management system is programmed to implement a first EWMA signal filter F1, wherein B includes historical EWMA current calculation as the average of the EWMA of the average current load A and one or more previously calculated battery module current loads.

21. The material handling vehicle of claim 1, wherein the battery management system is programmed to calculate successive running time currents IR1, IR2, IR3, etc., by means of sampling periods associated with the historical EWMA current calculation D of the average value C and the second EWMA signal filter F2, progressing over time.

22. The material handling vehicle of claim 21, wherein the sampling periods associated with the historical EWMA current calculation D of the average value C and the second EWMA signal filter F2 are all advanced by time interval t1 to calculate the successive running time currents IR1, IR2, IR3, etc.

23. The material handling vehicle as described in claim 1, wherein: The battery management system is programmed to implement a first EWMA signal filter F1, wherein B includes historical EWMA current calculations as the average of the EWMA of the average current load A and one or more previously calculated battery component current loads. The battery management system is programmed to calculate successive operating time currents IR1, IR2, IR3, etc., by progressively advancing sampling periods associated with the historical EWMA current calculation D using the average value C and the second EWMA signal filter F2; and The sampling periods associated with the historical EWMA current calculation D of the average value C and the second EWMA signal filter F2 are all advanced by time interval t1 to calculate the successive running time currents IR1, IR2, IR3, etc.

24. The material handling vehicle of claim 1, wherein the material handling subsystem, the drive subsystem, and the vehicle control hardware are configured to cooperate in performing the plurality of pick-up / place-down operations, such that the actual current load I on the battery assembly cycles between local maximum and local minimum values ​​multiple times within a time interval t1.

25. The material handling vehicle of claim 24, wherein the difference between the local maximum and the local minimum is at least approximately 1000 mA and the time interval t1 is approximately 1 minute.

26. The material handling vehicle of claim 24, wherein the difference between the local maximum and the local minimum is at least approximately 1000 mA and the time interval t1 ≤ 1 minute.

27. The material handling vehicle of claim 26, wherein both the local maximum and local minimum values ​​are greater than 0 mA.

28. The material handling vehicle of claim 26, wherein the local maximum value is greater than zero amperes and the local minimum value is less than or equal to 0 mA.

29. The material handling vehicle of claim 28, wherein the difference between the local maximum value and the local minimum value is at least approximately 1000 mA and less than approximately 5000 mA.

30. The material handling vehicle as claimed in claim 1, wherein The material handling subsystem, drive subsystem, and vehicle control hardware are configured to cooperate in performing the multiple pick-up / place-down operations, such that the actual current load I on the battery assembly cycles multiple times within a time interval t1 between local maximum and local minimum values ​​that differ by at least approximately 1000 mA and less than approximately 5000 mA. The battery management system is programmed to implement a first EWMA signal filter F1, wherein B includes historical EWMA current calculations as the average of the EWMA of the average current load A and one or more previously calculated battery component current loads. The battery management system is programmed to calculate successive runtime currents IR1, IR2, IR3, etc. by advancing the sampling period in time and associating it with the historical EWMA current calculation D of the average value C and the second EWMA signal filter F2. The sampling periods associated with the historical EWMA current calculation D of the average value C and the second EWMA signal filter F2 are all advanced by time interval t1 to calculate the successive running time currents IR1, IR2, IR3, etc.; and 。 31. A method for calculating the remaining battery runtime of a removable material handling vehicle's battery assembly and automatically controlling the material handling vehicle based on the calculated remaining battery runtime, wherein: The material handling vehicle includes a material handling subsystem, a drive subsystem, vehicle control hardware, and a removable battery assembly; The vehicle control hardware may be dedicated to the material handling subsystem, drive subsystem, or removable battery assembly, or a combination thereof. The material handling subsystem, drive subsystem, and vehicle control hardware are configured to cooperate under power from a removable battery module to perform multiple pick-up / placement operations, wherein the pick-up / placement operations are characterized by a minimum duration. ; as well as The removable battery assembly includes a battery management system and the method includes utilizing the battery management system to Input or generate a state-of-charge (SOC) signal representing the state of charge (SOC) of the battery assembly. Implement the first EWMA signal filter F1 to calculate the current I. C sequence ( The current calculation is performed in increments of time interval t1 and includes... Furthermore, A includes the average current load on the battery within time interval t1, and B includes a predetermined current load or historical EWMA current calculations that are earlier in time than the average current load A. Including the first weighted parameter, and , Implement the second EWMA signal filter F2 to calculate the runtime current I. R The running time current calculation includes And C includes the current calculation I from the first EWMA signal filter F1. C Multiple sequences ( In the time envelope t E The average value within the range, D includes the current calculation I that is earlier in time than the current from the first EWMA signal filter F1. C Multiple sequences ( Historical EWMA current calculations for at least one sequence in ) Including the second weighted parameter, where ,and And implement the remaining running time calculation R, which includes ;as well as The method also includes using vehicle control hardware to make a functional response to the runtime calculation R.

32. The method of claim 31, wherein: The vehicle control hardware of the material handling subsystem includes a user interface lifting / lowering control device and supporting electronics; and The method also includes using a lift / lower control device and supporting electronics to calculate R based on the running time, or automatically cutting off, gradually limiting, or otherwise disabling the lift / lower function of the material handling vehicle when the calculated R drops below a predetermined threshold.

33. The method of claim 31, wherein: The vehicle control hardware of the material handling subsystem includes a user interface-driven control device and supporting electronics; and The method also includes using a drive mode control device and supporting electronics to calculate R based on runtime, or automatically cutting off, gradually limiting, or otherwise disabling a specific drive mode of the material handling vehicle when the runtime-calculated R drops below a predetermined threshold.

34. The method of claim 31, wherein: The vehicle control hardware for the material handling subsystem includes battery hardware and supporting electronics; and The method also includes calculating R based on runtime, or automatically changing, enabling, or disabling battery hardware and supporting electronics when the runtime-calculated R drops below a predetermined threshold.

35. The method of claim 34, wherein: Battery hardware and supporting electronics include visual runtime displays on the battery or elsewhere on the vehicle; and The method also includes gradually changing the runtime indication on the visual runtime display based on the runtime calculated as R.

36. A vehicle comprising a drive subsystem, a removable battery pack, and vehicle control hardware, wherein: The vehicle control hardware may be dedicated to the drive subsystem or removable battery components, or may be shared by a combination of these. The drive subsystem and vehicle control hardware are configured to cooperate under power from the removable battery pack; The removable battery assembly includes a battery management system, which is programmed to: Input or generate a state-of-charge (SOC) signal representing the state of charge (SOC) of the battery assembly. Implement the first EWMA signal filter F1 to calculate the current I. C sequence ( ), Implement the second EWMA signal filter F2 to calculate the runtime current I. R The running time current calculation I R Including the current calculation I from the first EWMA signal filter F1 C ,as well as Implement the remaining runtime calculation R, which includes ;as well as The vehicle control hardware is programmed to make functional responses to runtime calculations R.

37. The vehicle of claim 36, further comprising a material handling subsystem, wherein: Vehicle control hardware may be dedicated to a material handling subsystem, drive subsystem, or removable battery assembly, or may be shared by a combination of these; and The material handling subsystem, drive subsystem, and vehicle control hardware are configured to cooperate under power from the removable battery assembly to perform multiple pick-up / place-down operations.

38. The vehicle of claim 36, wherein the first EWMA signal filter F1 includes historical EWMA components and the second EWMA signal filter F2 includes historical EWMA components.

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