Battery system for industrial vehicle

Abstract

A battery system for an industrial vehicle, the industrial vehicle including a frame having a vehicle profile defined by a front boundary, a rear boundary, a left boundary, and a right boundary of the frame, the left and right boundaries being at least partially defined by opposing outermost left and right portions of respective left and right sides of a battery compartment. The battery system includes a battery and a ballast assembly, with at least a portion of the ballast assembly positioned below the battery. The battery system further includes a first sensor assembly positioned below the battery at one of the left or right sides of the battery compartment. The first sensor assembly is entirely within the front, rear, left, and right boundaries of the frame so as to not increase the vehicle profile. The first sensor assembly includes a sensing device that monitors an area adjacent to the corresponding left or right side of the vehicle.

Description

Technical Field

[0001] This disclosure relates to a battery system for use in industrial vehicles. Background Technology

[0002] Industrial vehicles are typically used for picking inventory in warehouses and distribution centers. These vehicles usually include a power unit, which may include a battery system. The vehicles also have control structures for controlling their operation and movement.

[0003] In a typical inventory picking operation, the operator completes an order from available inventory items located in storage areas along one or more aisles along a warehouse or distribution center. For industrial vehicles, it is advantageous to adjust their dimensions to properly fit the aisles of the warehouse or distribution center. Summary of the Invention

[0004] According to various aspects of the embodiments, a battery system for an industrial vehicle is disclosed. The industrial vehicle includes a frame having a vehicle profile defined by a front boundary, a rear boundary, a left boundary, and a right boundary of the frame, the left and right boundaries being at least partially defined by opposing outermost left and right portions of respective left and right sides of a battery compartment. The battery system includes a battery and a counterweight assembly housed within the battery compartment, wherein at least a portion of the counterweight assembly is positioned below the battery. The system also includes a first sensor assembly positioned below the battery at one of the left or right sides of the battery compartment, wherein the first sensor assembly is entirely within the front, rear, left, and right boundaries of the frame to avoid adding to the vehicle profile. The first sensor assembly includes sensing devices for monitoring areas adjacent to the corresponding left or right side of the vehicle.

[0005] The battery may be a replacement battery that is smaller than the original equipment manufacturer (OEM) battery in at least one of the height, width, or depth dimensions, and is used to replace the OEM battery.

[0006] The counterweight assembly may include a first cutout portion for receiving the first sensor assembly, wherein the first cutout portion allows manipulation of the first sensor assembly without removing the battery or the counterweight assembly from the industrial vehicle.

[0007] The battery system may also include a second sensor assembly positioned below the battery on the opposite side of the left or right side of the battery compartment, wherein the second sensor is entirely within the front, rear, left, and right boundaries of the frame so as not to add to the vehicle profile. The second sensor assembly may include sensing devices that monitor the corresponding area adjacent to the left or right side of the vehicle.

[0008] The counterweight assembly may include a first cutout for receiving a first sensor assembly and a second cutout for receiving a second sensor assembly. The first and second cutouts allow manipulation of the first and second sensor assemblies without removing the battery or counterweight assembly from the industrial vehicle.

[0009] The height of the operator compartment floor above the ground can be the same before and after the battery is installed in the vehicle.

[0010] The system may also include a front sensor assembly and a rear sensor assembly. The front sensor assembly and the rear sensor assembly, together with the first sensor assembly and the second sensor assembly, can constitute a vehicle sensor assembly.

[0011] Vehicle sensor components can be provided to monitor the 360-degree area around a vehicle.

[0012] According to various aspects of the embodiments, an object detection assembly for an industrial vehicle is disclosed. The industrial vehicle includes a battery compartment, a replacement battery (which is smaller than an original equipment manufacturer (OEM) battery used to replace the replacement battery in at least one of the height, width, or depth dimensions), and a counterweight assembly. At least a first portion of the counterweight assembly is positioned below the replacement battery within the battery compartment. The object detection assembly includes a first sensing device in a first cutout portion of the counterweight assembly positioned below the replacement battery. The first sensing device has an unobstructed field of view on one of the left or right sides of the industrial vehicle. The object detection assembly also includes a second sensing device in a second cutout portion of the counterweight assembly positioned below the replacement battery. The second sensing device has an unobstructed field of view on the other side of the left or right side of the industrial vehicle.

[0013] The first and second sensing devices can be positioned within the outer contour lines of the vehicle.

[0014] The first and second cutout portions can be opened to the respective left or right side of the industrial vehicle to allow manipulation of the first and second sensing devices without removing replacement batteries or counterweight components from the industrial vehicle.

[0015] The object detection component may also include a front sensor component with front sensing devices and a rear sensor component with rear sensing devices.

[0016] Each of the first sensing device, the second sensing device, the front sensing device, and the rear sensing device may be located within the front boundary, rear boundary, left boundary, and right boundary of the frame of the industrial vehicle.

[0017] The first sensing device, the second sensing device, the front sensing device, and the rear sensing device can work together to monitor an area extending 360 degrees around the vehicle.

[0018] The counterweight assembly may include a second part positioned in front of or behind the battery in the battery compartment.

[0019] The height of the operator compartment floor above the ground can be the same before and after the battery replacement is installed in the vehicle. Attached Figure Description

[0020] Figure 1 This is a perspective view of an industrial vehicle according to an embodiment; Figure 2 This is a partial perspective view of an industrial vehicle according to an embodiment; Figure 3 This is a top view of an industrial vehicle according to an embodiment, and it illustrates the object detection component; Figure 4 This is a partial perspective view of an industrial vehicle according to an embodiment; Figure 5A This is a partial side view of the sensor assembly and battery compartment according to an embodiment; and Figure 5B This is a partial side view of the sensor assembly and battery compartment according to an embodiment. Detailed Implementation

[0021] The following is a broad description of numerous different embodiments of this disclosure. This description should be construed as merely exemplary and does not describe every possible embodiment, as describing every possible embodiment would be impractical, if not impossible, and it will be understood that any feature, characteristic, component, composition, ingredient, product, step, or method described herein may be removed, combined with, or substituted for any other feature, characteristic, component, composition, ingredient, product, step, or method described herein. It should be understood that many combinations of the described and illustrated embodiments are contemplated, and particular attention to one embodiment does not exclude its inclusion in combinations of other described embodiments. Many alternative embodiments may also be implemented using either current technology or technology developed after the filing date of this patent, and these embodiments will still fall within the scope of the claims. All publications and patents cited herein are incorporated herein by reference.

[0022] Now refer to the attached diagram. Figure 1An exemplary industrial vehicle 10 is illustrated, which includes a load-handling assembly 12 and a power unit 14. The load-handling assembly 12 of the illustrated exemplary vehicle 10 includes a pair of forks 16; however, it should be understood that the load-handling assembly 12 may include additional or alternative load-handling features, such as a mast, load platform, collection cage, and / or other structures. The illustrated exemplary vehicle 10 also includes an operator compartment 13, a chassis 17, a plurality of load-bearing wheels 19, and a battery system 20. The operator compartment 13 includes a floor 15 on which an operator can stand while driving the vehicle 10. While this disclosure is made with reference to the illustrated vehicle 10, it will be apparent to those skilled in the art that the embodiments disclosed herein can be used in other types of industrial vehicles, and the following description of the embodiments with reference to the accompanying drawings should not be limited to the type of vehicle 10 shown, unless otherwise stated. Furthermore, the embodiments disclosed herein can be used in vehicles that do not include a load-handling assembly, such as tractor-trailers.

[0023] Now for reference Figure 2 and Figure 3 The battery system 20 of the exemplary vehicle 10 shown includes a battery compartment 22 for housing a battery 24 and a frame 30 defining a vehicle profile 32. The vehicle profile 32 represents vehicle dimensions and may include overall vehicle height, floor height, overall vehicle width, and overall vehicle length. The vehicle profile 32 of the exemplary vehicle 10 is defined by a front boundary 34, a rear boundary 36, a left boundary 38, and a right boundary 40 of the frame 30, wherein the left and right boundaries 38, 40 are at least partially defined by the opposite outermost left and right portions 38a, 40a of the respective left and right sides 22L, 22r of the battery compartment 22, the front boundary 34 is defined by the foremost portion 34a of the vehicle frame 30 extending in front of the power unit 14, and the rear boundary 36 is defined by the vertical surface 36a of the forks 16. A plurality of load-bearing wheels 19 of the exemplary vehicle 10 are flush with the chassis 17 and within the vehicle profile 32; that is, the load-bearing wheels 19 do not add to the vehicle profile 32.

[0024] like Figure 4 As shown, the battery system 20 also includes a counterweight assembly 42, which, in the illustrated exemplary embodiment, includes a lower counterweight 42a and an upper counterweight 42b. A first portion 43 of the lower counterweight 42a is positioned below the battery 24, and a second portion 45 of the lower counterweight 42a is positioned adjacent to the battery 24 (see [reference]). Figure 2 and Figure 4 This gives the exemplary lower counterweight 42a an "L"-shaped appearance, see [reference]. Figure 4 and Figure 5AThe upper counterweight 42b is positioned between and adjacent to the battery 24 and the front wall 47 of the chassis, and above the second portion 45 of the lower counterweight 42a. According to an embodiment, the counterweight assembly 42 and the battery 24 can be arranged such that their mass and center of gravity have a positive impact on the rollover stability of the vehicle 10.

[0025] refer to Figure 5A The battery system 20 additionally includes a first sensor assembly 50 located below the battery 24 at one of the left or right sides 22L, 22r of the battery compartment 22. The first sensor assembly 50 is positioned on the vehicle 10 such that it is entirely within the front, rear, left, and right boundaries 34, 36, 38, 40 of the frame 30 without increasing the vehicle profile 32. The first sensor assembly 50 includes a first sensing device 52 that monitors a corresponding area A1 adjacent to the left or right side of the vehicle 10. See [link to relevant documentation]. Figure 3 The first sensing device 52 may include, for example, a laser sensor for object detection (i.e., to detect the presence of an object in area A1 near vehicle 10). Examples of objects detected by the sensor assembly as discussed herein include pedestrians, other industrial vehicles, shelves / racks, walls, stairs, loads, pallets, and similar objects in a warehouse environment.

[0026] The battery system 20 of vehicle 10 additionally includes a second sensor assembly 62 located below battery 24 on the other side of the left or right side 22l, 22r of battery compartment 22, see [link to documentation]. Figure 5B Similar to the first sensor assembly 50, the second sensor assembly 62 is positioned on the vehicle 10 such that it is entirely within the front, rear, left, and right boundaries 34, 36, 38, and 40 of the frame 30 without adding to the vehicle profile 32. The second sensor assembly 62 includes a second sensing device 64 that monitors a corresponding area A2 adjacent to the left or right side of the vehicle 10. See [link to relevant documentation]. Figure 3 The second sensing device 64 may include, for example, a laser sensor for object detection (i.e., to detect the presence of an object in area A2 near vehicle 10).

[0027] Now for reference Figure 4 and Figure 5AThe counterweight assembly 42 includes a first cutout portion 60 for receiving a first sensor assembly 50 and a second cutout portion 66 for receiving a second sensor assembly 62. The first and second cutout portions 60, 66 may each be at least partially located below the battery 24 and at least partially located between the counterweight assembly 42 and the rear wall 49 of the chassis. The first and second cutout portions 60, 66 are open to the respective left or right side of the industrial vehicle 10 to allow manipulation of the first and second sensor assemblies 50, 62 without removing the battery 24 or the counterweight assembly 42 from the vehicle 10. For example, the first and second sensor assemblies 50, 62 can be installed, serviced, repositioned, or removed without requiring the removal of the battery 24 or the counterweight assembly 42 from the vehicle 10. This is advantageous because it allows quick access to the first and second sensor assemblies 50, 62 for service and / or adjustment without removing or adjusting the battery 24 or the counterweight assembly 42. The first sensor side cutout 61 and the second sensor side cutout 63 may be located on opposite sides of the first sensor assembly 50, and the third sensor side cutout 65 and the fourth sensor side cutout 67 may be located on opposite sides of the second sensor assembly 62. The first and third sensor side cutouts 61 and 65 may be formed in portions 45 of the counterweight assembly located in front of the respective first and second sensor assemblies 50 and 62, and the second and fourth sensor side cutouts 63 and 67 may be formed in portions of the chassis rear wall 49 or vehicle side skirt 51 located behind the respective first and second sensor assemblies 50 and 62. The side cutouts 61, 63, 65, and 67 provide magnified views for the first and second sensor assemblies 50 and 62.

[0028] According to an embodiment, battery 24 may be a replacement battery 24r that is smaller than the original equipment manufacturer (OEM) battery in at least one of the dimensions of height, width, or depth, and is used to replace the OEM battery. For example, the replaced OEM battery may be a lead-acid battery, and the replacement battery may be a lithium-ion (Li-ion) battery, wherein the replacement Li-ion battery is much lighter than the OEM lead-acid battery and includes the same or greater energy storage capacity as the OEM lead-acid battery. According to an embodiment, the replacement Li-ion battery may also have a smaller energy storage capacity than the OEM lead-acid battery.

[0029] According to the embodiment, before and after the replacement battery 24r is installed on the vehicle 10 to replace the OEM battery, the height and / or surface area of ​​the floor 15 of the operator compartment 13 can be the same. That is, modifications made to the vehicle 10 for installing the battery system 20 including the replacement battery 24r according to this embodiment do not change the height and / or surface area of ​​the floor 15. Therefore, operators of vehicles including the battery system 20 according to the embodiments disclosed herein do not need to become accustomed to floor assemblies with different heights and / or surface areas, thereby reducing or avoiding potential reductions in operator efficiency due to changes in the height and / or surface area of ​​the floor 15.

[0030] According to another aspect, the object detection assembly 70 of the exemplary industrial vehicle 10 includes a first sensor assembly 50, a second sensor assembly 62, a front sensor assembly 72, and a rear sensor assembly 76. For example... Figure 1 As shown, both the first sensor assembly 50 and the second sensor assembly 62 can be completely positioned within the outer contour line RL of the vehicle 10, where the outer contour line RL is defined by the outermost portion of the vehicle width W. See [reference needed]. Figure 1 .

[0031] As in Figure 3 As most clearly shown, the front sensor assembly 72 is entirely located within the front, rear, left, and right boundaries 34, 36, 38, 40 of the vehicle frame 30 without increasing the vehicle profile 32. In the illustrated exemplary embodiment, the front sensor assembly 72 is positioned on the power unit 14, but the front sensor assembly 72 may be mounted to other components at or around the front of the vehicle 10. The front sensor assembly 72 includes a front sensing device 74 that monitors a region A3 adjacent to the front side of the vehicle 10. The front sensing device 74 may include, for example, a laser sensor for object detection (i.e., to detect the presence of an object near the vehicle 10 in region A3). A front cutout 73 may be provided at the front of the vehicle frame 30 to increase the area A3 sensed by the front sensing device 74.

[0032] Still referencing Figure 3 The rear sensor assembly 76 is also entirely located within the front, rear, left, and right boundaries 34, 36, 38, and 40 of the vehicle frame 30 so as not to increase the vehicle profile 32. In the illustrated exemplary embodiment, the rear sensor assembly 76 is positioned below the load handling assembly 12, such as on a mast between mast rails; however, the rear sensor assembly 76 may be mounted to other components at or around the rear of the vehicle 10. The rear sensor assembly 76 includes a rear sensing device 78 that monitors a region A4 adjacent to the rear side of the vehicle 10, see [link to documentation]. Figure 3The rear sensing device 78 may include, for example, a laser sensor for object detection (i.e., to detect the presence of an object near the vehicle 10 in area A4). A rear cutout 79 may be provided at the rear of the vehicle frame 30 to increase the area A4 sensed by the rear sensing device 78.

[0033] The object detection assembly 70, consisting of a first sensor assembly 50, a second sensor assembly 62, a front sensor assembly 72, and a rear sensor assembly 76, monitors a 360-degree area around the vehicle 10. Specifically, the combined areas A1, A2, A3, and A4 monitored by the respective first, second, front, and rear sensor assemblies 50, 62, 72, and 76 completely cover the 360-degree area around the vehicle 10 without increasing the vehicle outline 32. In other words, each of the first, second, front, and rear sensor assemblies 50, 62, 72, and 76 is positioned on the vehicle 10, completely within the vehicle outline 32, and within the outer outline RL of the vehicle 10. (See [reference]). Figure 1 .

[0034] Battery system 20 and / or object detection component 70 may be original features included on newly manufactured industrial vehicles, or may be utilized when modifying or retrofitting an existing industrial vehicle to include battery system 20 and / or object detection component 70. For example, a currently used vehicle may be modified by either altering the battery compartment or replacing it with a replacement battery compartment (not shown). The altered / replaced battery compartment may also be configured to receive a replacement battery 24r that is smaller and lighter than the original equipment manufacturer (OEM) battery 24 in at least one of the height, width, or depth dimensions, and is used to replace the OEM battery 24. It is also contemplated that a currently used vehicle may be modified by replacing the OEM battery 24 with the replacement battery 24r, wherein the additional space available in battery compartment 22 due to the replacement battery 24r being smaller than the OEM battery 24 in at least one of the height, width, or depth dimensions can be used to accommodate counterweight component 42 and first and second cutout portions 60, 66. Alternatively or additionally, the first sensor assembly 50 and the second sensor assembly 62 may be added to the vehicle, for example, to the first and second cutout portions 60, 66, respectively, and the front and rear sensor assemblies 72, 76 may be added to the front and rear of the vehicle 10, respectively. It is also anticipated that the front and rear sensor assemblies 72, 76 may already exist on the currently used vehicle, in which case only the first and second sensor assemblies 50, 62 need to be added to complete the object detection assembly 70.

[0035] Industrial vehicles are frequently used in warehouses or distribution centers, which include confined spaces and many other moving objects such as people or other industrial vehicles. Industrial vehicles that include the features discussed herein (i.e., battery system 20 and / or object detection component 70) offer benefits in maintaining and / or improving the efficiency of industrial vehicles in confined spaces. The ability to monitor 360 degrees around the vehicle without increasing the vehicle profile provides the benefit of obstacle detection / avoidance without compromising the ability to operate the vehicle in such confined spaces. As discussed above, object detection component 70 and battery system 20 can be included in newly manufactured industrial vehicles or can be utilized when modifying or refurbishing existing industrial vehicles already in use. This is particularly important if the existing vehicle does not include an object detection system. By modifying an existing vehicle to include battery system 20 and / or object detection component 70, the existing vehicle gains the ability to monitor 360 degrees around the vehicle without increasing the vehicle profile 32 or changing the height of the operator platform floor. Otherwise, such an increase in vehicle profile and / or change in the height of the operator's platform floor would make the vehicle more cumbersome, hinder its ability to operate at peak efficiency, and / or reduce the operator's efficiency in operating the vehicle. According to the embodiments disclosed herein, having a vehicle that includes 360-degree surveillance around the vehicle while maintaining its profile allows the vehicle to perform normal functions unimpeded, such as moving through narrow passages and maneuvering around objects, people, and other industrial vehicles.

[0036] Embodiments of this application have been described in detail and by way of reference, and it will be apparent that modifications and variations are possible without departing from the scope of the appended claims.

Claims

1. A battery system for an industrial vehicle, the industrial vehicle comprising a frame having a vehicle profile defined by a front boundary, a rear boundary, a left boundary, and a right boundary of a frame, the left boundary and the right boundary being at least partially defined by opposing outermost left and right portions of respective left and right sides of a battery compartment, the battery system comprising: A battery, which is housed in a battery compartment; A counterweight assembly, wherein at least a portion of the counterweight assembly is positioned below the battery; as well as A first sensor assembly is positioned below the battery on either the left or right side of the battery compartment, wherein the first sensor assembly is entirely within the front, rear, left, and right boundaries of the frame so as not to add to the vehicle profile. The first sensor assembly includes a sensing device that monitors the area adjacent to the corresponding left or right side of the vehicle.

2. The battery system of claim 1, wherein the battery is a replacement battery smaller than an original equipment manufacturer (OEM) battery in at least one of the dimensions of height, width, or depth, the replacement battery being used to replace the OEM battery.

3. The battery system of claim 1 or claim 2, wherein the counterweight assembly includes a first cutout portion for receiving the first sensor assembly, wherein the first cutout portion allows manipulation of the first sensor assembly without removing the battery or the counterweight assembly from the industrial vehicle.

4. The battery system as claimed in any of the preceding claims further includes a second sensor assembly located below the battery on the other side of the left or right side of the battery compartment, wherein the second sensor is entirely within the front, rear, left, and right boundaries of the frame to avoid adding to the vehicle profile, wherein the second sensor assembly includes sensing devices for monitoring the area adjacent to the corresponding left or right side of the vehicle.

5. The battery system of claim 4, wherein the counterweight assembly includes a first cutout portion for receiving a first sensor assembly and a second cutout portion for receiving a second sensor assembly, wherein the first and second cutout portions allow manipulation of the first and second sensor assemblies without removing the battery or counterweight assembly from the industrial vehicle.

6. The battery system of claim 4 or claim 5 further includes a first sensor-side cutout and a second sensor-side cutout located on opposite sides of the first sensor assembly for magnifying the field of view of the first sensor assembly.

7. The battery system of claim 6 further includes a third sensor-side cutout and a fourth sensor-side cutout located on opposite sides of the second sensor assembly for magnifying the field of view of the second sensor assembly.

8. The battery system as claimed in any of the preceding claims, wherein the height of the operator compartment floor above the ground is the same before and after the battery is installed in the vehicle.

9. The battery system as claimed in any of the preceding claims, wherein the surface area of ​​the operator compartment floor is the same before and after the replacement battery is installed in the vehicle.

10. An object detection assembly for an industrial vehicle, the industrial vehicle including a battery compartment, a replacement battery, and a counterweight assembly, the replacement battery being smaller than an original equipment manufacturer (OEM) battery for which the replacement battery is intended to replace in at least one of a height, width, or depth dimension, wherein at least a first portion of the counterweight assembly is positioned below the replacement battery within the battery compartment, the object detection assembly comprising: A first sensing device is positioned in a first cutout portion of a counterweight assembly below the replacement battery, and the first sensing device has an unobstructed view of one of the left or right sides of the industrial vehicle. as well as The second sensing device is positioned in a second cutout portion of the counterweight assembly below the replacement battery, and the second sensing device has an unobstructed view of the other side of the industrial vehicle, either the left or right side.

11. The object detection component of claim 10, wherein the first sensing device and the second sensing device are each positioned within the outer contour line of the vehicle.

12. The object detection assembly of claim 10 or claim 11, wherein the first cut portion and the second cut portion are open to the respective left or right side of the industrial vehicle to allow manipulation of the first and second sensing devices without removing a replacement battery or counterweight assembly from the industrial vehicle.

13. The object detection assembly of claim 12 further includes a first sensor-side cutout and a second sensor-side cutout located on opposite sides of the first sensing device for magnifying the field of view of the first sensing device.

14. The object detection assembly of claim 13 further includes a third sensor-side cutout and a fourth sensor-side cutout located on opposite sides of the second sensing device for magnifying the field of view of the second sensing device.

15. The object detection assembly according to any one of claims 10-14, further comprising a front sensor assembly having a front sensing device and a rear sensor assembly having a rear sensing device.

16. The object detection assembly of claim 15, wherein each of the first sensing device, the second sensing device, the front sensing device, and the rear sensing device is located within the front boundary, the rear boundary, the left boundary, and the right boundary of the frame of the industrial vehicle.

17. The object detection assembly of claim 15 or claim 16 further includes a front cutout provided adjacent to the front sensing device at the front of the frame for magnifying the field of view of the front sensing device, and a rear cutout provided adjacent to the rear sensing device at the rear of the frame for magnifying the field of view of the rear sensing device.

18. The object detection assembly of any one of claims 15-17, wherein the first sensing device, the second sensing device, the front sensing device, and the rear sensing device jointly monitor an area extending 360 degrees around the vehicle.

19. The object detection assembly of any one of claims 10-18, wherein the counterweight assembly includes a second portion positioned in the battery compartment in front of or behind the replacement battery.

20. The object detection component according to any one of claims 10-19, wherein at least one of the following: The height of the operator compartment floor above the ground is the same before and after the replacement battery is installed in the vehicle, or the surface area of ​​the operator compartment floor is the same before and after the replacement battery is installed in the vehicle.

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