Stackable battery assembly for container handling vehicles

Abstract

The present disclosure relates to a method of charging a first battery assembly arranged for powering a robot for both moving the robot along a track of a storage grid and moving a gripping device of the robot relative to a body part of the robot, by transferring electrical energy from a second battery assembly to the first battery assembly.

Description

Technical Field

[0001] This disclosure relates to batteries for container handling vehicles. More specifically, this disclosure relates to a stackable battery assembly for container handling vehicles, and a method for charging the battery assembly. Background Technology

[0002] Traditional storage solutions typically involve arranging goods on rows of shelves within a warehouse. The shelf location of each item is recorded in an inventory list, and goods are retrieved from the shelves by pickers. As goods enter and leave the warehouse, the shelves are replenished as needed, and the inventory list is updated.

[0003] Robotic pickers and automated inventory management systems can assist warehouse staff. Automated transport systems can also be implemented in traditional warehouse facilities to move goods from their storage locations to picking and / or packing stations.

[0004] An alternative to traditional warehouse installations is an automated storage and retrieval system (AS / RS), in which robots retrieve items from recorded locations within the warehouse and deliver them to packing stations or ports. This system reduces or eliminates the space required to navigate between rows of shelves to access inventory, thus eliminating the need for wide aisles within the warehouse. One example of such a system involves arranging goods in boxes or containers configured to be stacked side-by-side within a three-dimensional grid. A track system with a track grid is arranged on top of the grid, along which robotic container handling vehicles configured to lift containers from the grid can travel / move. The container handling vehicles are configured to transport containers from the grid and deliver them to ports or stations outside the grid, allowing the goods inside the containers to be picked up and packed.

[0005] The container transport vehicle is battery powered, and a charging operation can be performed to recharge the battery when the battery power of the container vehicle is low.

[0006] Various aspects of the invention described in this application are set forth in the claims. Attached Figure Description

[0007] The present disclosure will now be described in more detail with reference to several exemplary embodiments illustrated in the accompanying drawings, in which: Figure 1 A perspective view of a storage system is shown, which includes a grid and multiple robotic container handling vehicles configured to retrieve and / or rearrange goods stored within the grid. Figure 2 It shows Figure 1 A top view of the system; Figure 3AIt shows that it is suitable for use in Figure 1 Side view of the first robotic container handling vehicle used in the system; Figure 3B It shows that it is suitable for use in Figure 1 Side view of the second robotic container handling vehicle used in the system; Figure 3C yes Figure 3B A three-dimensional side view of the robot; Figure 4 A computing device for implementing the operations described herein is shown; Figure 5A and Figure 5B It is a 3D view of the battery assembly; Figure 6 It is a 3D view of a container handling vehicle and multiple battery modules stacked together; Figure 7 This is a 3D view of the robotic vehicle, showing its gripping device and battery assembly from below. Figure 8 This is a cross-sectional view of the battery assembly; Figure 9 This is a schematic diagram of the battery assembly stack on top of the charger located in the grid; Figure 10 A flowchart illustrating method steps that can be performed according to this disclosure is shown, and Figure 11 A flowchart illustrating the method steps that can be performed according to this disclosure is shown. Detailed Implementation

[0008] In summary, this disclosure relates to a robot capable of traveling on a track grid of a storage system and raising and lowering a gripper that can independently pick up containers and lock them to their lids. Because the gripper is capable of locking the lid while simultaneously picking up the container, the robot can remove the lid from the container, thus eliminating the need to remove the lid only when the container is at the outlet port of the storage system, which would slow down the operation (and also eliminating the need for a dedicated robot for lid removal).

[0009] Overview of Automated Storage and Retrieval Systems

[0010] refer to Figure 1In the embodiment shown, the grid 100 comprises a frame consisting of a plurality of generally linear, adjacent vertical columns 102 formed between vertical frame members 104 and extending in the X direction 108 and the Y direction 110. The grid elements can be made of any suitable material; for example, the frame members can be made of extruded aluminum. Storage containers or boxes 112 are preferably stacked on top of each other in a self-supporting manner along the Z direction 114 in the columns 102, forming storage volumes for storage units of the respective boxes 112, which extend in the X direction 108, Y direction 110, and Z direction 114.

[0011] A track system or network 116 is formed on top of grid 100 and includes pairs of vehicle tracks or rails 118a, 118b and 120a, 120b extending in the X direction 108 and Y direction 110, respectively. A robotic container handling vehicle or robot 122 (which may have a range of sizes, shapes, and functions) is set up and configured to run on tracks 118, 120 (which may be a track grid) and transport boxes 112 in both the X direction 108 and Y direction 110. Robot 122 is also configured to lift / lower boxes 112 from column 102 into column 114 in the Z direction via one or more belts, cables, ropes, etc., optionally guided by vertical frame members 104. Robot 122 accesses boxes 112 via access openings 124 located above column 102 and formed between tracks 118 and 120.

[0012] Some columns 102 can be used for purposes other than storing the bins. For example, port columns 126, 128 include port columns or access columns that allow bins 112 to be moved into and / or out of grid 100. Port columns 126, 128 provide vertical channels for lifting bins 112 from ports 130, 132 or lowering bins 112 into the ports. Ports 130, 132 in Figure 1 The port is shown at the lowest horizontal level of the grid; however, the port can be located at any vertical position along the column. The corresponding port columns 126, 128 can be designated for removing (“unloading”) box 112 from grid 100 and / or returning or delivering (“picking up”) the box to the grid. Therefore, ports 130, 132 are configured to allow the removal of box 112 and the (horizontal) reintroduction of the box into the associated port column. Therefore, ports 130, 132 may include a conveying device ( Figure 1(Not shown in the image) Box 112 can be lowered onto a conveyor and transported horizontally out of the port column. Port columns 126, 128 include openings or access points through which box 112 enters and exits the column. Additionally or alternatively, one or more battery columns 134 may be designated for storing stacks of battery components to power robot 122, and such battery columns 134 may accommodate corresponding chargers 136 for delivering charge to the battery components stacked within the battery columns 134.

[0013] Box 112 can be transported by robot 122 along the top of grid 100 to port columns 126, 128 and / or back from port columns, and from ports 130, 132 to a location outside grid 100, which may be an access station (not shown) for handling box 112 or its contents, such as a pick-up station for adding or removing contents from box 112. In an alternative example (not shown), box 112 may be transported to a port of another grid at the same or another horizontal level, or to an external facility. Transport of box 112 to and from ports 130 and 132 can be carried out by any suitable means (not shown), including conveyors, transport vehicles, lifting mechanisms, or robots.

[0014] refer to Figure 2 The illustrated embodiment provides a more detailed view of the XY configuration 200 of the track system 116 and the different types of robots 202, 204. The track system includes tracks 206, with vertical column access openings 124 defined between the tracks for accessing the bin 112. Tracks 206 can be any suitable type of track for allowing robots 202, 204 to travel along the X direction 108 and Y direction 110, including (not shown) recessed tracks for receiving wheels of a vehicle, or protruding tracks for engaging recesses of wheels. Each track 206 may include a single guide rail or multiple parallel guide rails in each of the X direction 108 and Y direction 110.

[0015] The first "cantilever" type robot 202 Figure 3AThe image, shown in more detail, includes a body (body portion) 300, a set of wheels 302, and a lifting device 304. The body 300 houses operating devices (not shown) for the robot 202, including a drive system, a power system, and a control system. The wheels 302 allow the robot 202 to move in one of the X and Y directions, while another set of wheels (not visible in this view) allows the robot to move in the other direction, in both cases, along corresponding tracks or rails 206. One or both sets of wheels can be raised or lowered to allow selective engagement with tracks, thereby enabling movement in the desired direction. The lifting device 304 includes a cantilever element 306 extending from the top of the body 300 in the XY plane; and a clamping device 308 capable of being raised and lowered relative to the cantilever element 306, for example, via one or more belts, cables, ropes, etc. The clamping device 308 is configured to releasably clamp or engage the box 112, for example, by a portion of the clamping box 112, or by engaging a suitably configured portion of the box 112 passively or actively.

[0016] The second "internal cavity" type robot 204 is in Figure 3B As shown in more detail below, and as an alternative to a cantilever lifting system, an internal cavity 310 is located within the body 300, and a lifting device 312 including a clamping device (not shown) is positioned within this internal cavity. In this case, the body 300 includes the robot's operating equipment and storage space for one or more boxes 112 for use, for example, during the transport of the boxes 112.

[0017] Figure 3C It shows Figure 3B A stereoscopic side view of the robot, in which you can see Figure 3B The first set of wheels, 302. Mentioned above but not mentioned in... Figure 3B Another set of wheels shown in Figure 3C The first set of wheels 302 is shown as wheel 303. Another set of wheels 303 is arranged perpendicular to the first set of wheels 302 to allow the robot 204 to roll along the X and Y directions using the first set of wheels 302 and the second set of wheels 303, respectively. Figure 3C The first set of wheels 302 and the second set of wheels 303 shown can be configured to independently lower and engage with the track (or raise and disengage from the track) to allow the robot 202 to traverse. Figure 2 The track device shown moves along the X and Y directions. Although Figure 3C The 3D diagram shown is Figure 3B Robot 204, however, should be understood that a similar arrangement of vertical wheels can also be applied. Figure 3A Robot 202 in the middle.

[0018] Control and monitoring systems

[0019] The control and monitoring of the automated storage and retrieval system (including monitoring and storing the location of the boxes and controlling the delivery, retrieval, and transport of the boxes, as well as robot route planning and collision avoidance) is handled by Figure 4 The control system shown communicates with the robot and / or other controllable system components to perform the control. This control can be performed locally or remotely and can be implemented by a processing system, such as a computing device. Therefore, the methods described herein can constitute all or part of a computer-implemented method, or a system configured to perform the methods described herein.

[0020] refer to Figure 4 A processing system 400 suitable for performing the methods described herein will now be described. Figure 4 A block diagram of one implementation of a processing system 400 is shown, which takes the form of a computing device within which an instruction set can run to cause the computing device to perform any or more methods described herein. In some implementations, the computing device may be connected to (e.g., networked to) other machines in a local area network (LAN), intranet, extranet, or the Internet. The computing device may operate at the capacity of a server or client machine in a client-server network environment, or at the capacity of a peer-to-peer machine in a peer-to-peer (or distributed) network environment. The computing device may be a personal computer (PC), tablet computer, set-top box (STB), personal digital assistant (PDA), cellular phone, networked home appliance, server, network router, switch, or bridge, or any machine capable of executing a set of instructions (sequentially or otherwise) specifying the actions to be taken by the machine. Furthermore, although only a single computing device is shown, the term "computing device" should also be understood to include any collection of machines (e.g., computers) that individually or collectively execute one or more instruction sets to perform any or more methods described herein.

[0021] An exemplary processing system 400 includes a processor 402, a main memory 404 (e.g., read-only memory (ROM), flash memory, dynamic random access memory (DRAM) such as synchronous DRAM (SDRAM) or Rambus DRAM (RDRAM), etc.), a static memory 406 (e.g., flash memory, static random access memory (SRAM), etc.), and a secondary memory (e.g., a data storage device 418), which communicate with each other via a bus 430.

[0022] Processor 402 represents one or more general-purpose processors, such as microprocessors, central processing units, etc. More specifically, processor 402 may be a Complex Instruction Set Computing (CISC) microprocessor, a Reduced Instruction Set Computing (RISC) microprocessor, a Very Long Instruction Word (VLIW) microprocessor, a processor implementing other instruction sets, or a processor implementing combinations of instruction sets. Processor 402 may also be one or more special-purpose processors, such as application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), digital signal processors (DSPs), network processors, etc. Processor 402 is configured to execute processing logic (instruction 422) to perform the operations and steps described herein.

[0023] The processing system 400 may also include a network interface device 408. The processing system 400 may also include any one of a video display unit 410 (e.g., a liquid crystal display (LCD) or a cathode ray tube (CRT)), an alphanumeric input device 412 (e.g., a keyboard or a touch screen), a cursor control device 414 (e.g., a mouse or a touch screen), and an audio device 416 (e.g., a speaker).

[0024] Obviously, Figure 4 Some features of the processing system 400 shown may be absent. For example, the processing system 400 may not require a display device 410 (or any associated adapter). This may be the case, for example, with a particular server-side computer device that is only used for its processing capabilities and does not need to display information to a user. Similarly, a user input device 412 may not be necessary. In its simplest form, the processing system 400 includes a processor 402 and main memory 404.

[0025] Data storage device 418 may include one or more machine-readable storage media (or more specifically, one or more non-transitory computer-readable storage media) 428 storing one or more instruction sets 422 embodying any or more of the methods or functions described herein. The instructions 422 may also reside wholly or at least partially within main memory 404 and / or processor 402 during execution by processing system 400, which also constitute computer-readable storage media 428.

[0026] The various methods described herein can be implemented by a computer program. A computer program may include computer code arranged to instruct a computer to perform one or more of the various methods described herein. The computer program and / or code for performing such methods may be provided to a device, such as a computer, on one or more computer-readable media or more generally on a computer program product. The computer-readable media may be transient or non-transient. One or more computer-readable media may be, for example, an electronic system, a magnetic system, an optical system, an electromagnetic system, an infrared system, or a semiconductor system, or a propagation medium for data transmission, such as for downloading code via the Internet. Alternatively, one or more computer-readable media may take the form of one or more physical computer-readable media, such as semiconductor or solid-state memory, magnetic tape, removable computer floppy disk, random access memory (RAM), read-only memory (ROM), rigid disk, or optical disk, such as CD-ROM, CD-R / W, or DVD.

[0027] A computer program can be run by processor 402 to perform the functions of the systems and methods described herein.

[0028] In implementation, the modules, components, and other features described herein may be implemented as discrete components or integrated into the functionality of hardware components such as ASICs, FPGAs, DSPs, or similar devices.

[0029] A "hardware component" is a tangible (e.g., non-transitory) physical component (e.g., a group or more processors) capable of performing a specific operation and which can be configured or arranged in a specific physical manner. A hardware component may include dedicated circuitry or logic permanently configured to perform a specific operation. A hardware component may be a dedicated processor, or may include dedicated processors such as field-programmable gate arrays (FPGAs) or ASICs. A hardware component may also include programmable logic or circuitry temporarily configured by software to perform a specific operation.

[0030] Therefore, the phrase “hardware component” should be understood to encompass tangible entities that can be physically constructed, permanently configured (e.g., hardwired) or temporarily configured (e.g., programmed) to operate in a particular manner or perform the particular operations described herein.

[0031] Furthermore, modules and components can be implemented as firmware or functional circuitry within a hardware device. Additionally, modules and components can be implemented as any combination of hardware devices and software components, or solely as software (e.g., code stored in or otherwise embodied in a machine-readable medium or transmission medium).

[0032] Operation of the automatic storage and retrieval system

[0033] In operation, each box 112 is assigned a unique identifier, which can be marked on the box 112 using a computer-readable identifier (e.g., a barcode, quick-response code, or RFID tag) to simplify identification of the box 112. The database of the processing system 400 stores the location of each box 112 associated with the unique identifier and optionally stores the contents of that box. When a box 112 is moved (e.g., when it is removed from grid 100), the database is updated to record the change in its location.

[0034] When it is necessary to retrieve box 112 from grid 100, under the control of processing system 400, robots 202 and 204 are routed via track system 116 to vertical column 102 including storage units. Box 112 is positioned at this storage unit according to a database, and lifting devices 304 and 312 (depending on robot type) are positioned above the corresponding access opening 124, adjacent to or below robots 202 and 204. Robots 202 and 204 lower gripping device 308, which engages, grips box 112, and lifts it to robots 202 and 204. Robots 202 and 204 then transport box 112 to, for example, unloading port columns 126 and 128 for delivery to ports 130 and 132 for further processing outside grid 100. If the target or designated box 112 is located below other boxes in the stack, robots 202, 204, or multiple robots possibly dedicated to this task, are controlled during the "digging" operation to temporarily or permanently lift and reposition the boxes above the target box 112 in sequence to retrieve the target box. It should be understood that other operations related to box 112 can be performed in a similar manner. For example, box 112 can be delivered to ports 130, 132 of pick-up port columns 126, 128 for storage in grid 100, gripped and lifted by robots 202, 204, and delivered to the desired storage unit, whereby, if necessary, boxes located above the desired position can be repositioned as discussed above.

[0035] Battery Components

[0036] Figure 5AA perspective view of battery assembly 500 is shown. Battery assembly 500 has a positive terminal 502 and a negative terminal 504 located on an upper surface 505 of battery assembly 500. The battery assembly also has a battery assembly clamping device 506 for releasably clamping the battery assembly to a clamping device 308 of robot 202. In this example, the battery assembly clamping device 506 is arranged to rotate about an axis substantially perpendicular to the upper surface of the battery assembly to move between an unclamped position and a clamped position, in which the clamping device 308 of robot 202 does not clamp onto the battery assembly 500 when descending onto it, and in the clamped position, the clamping device 308 of robot 202, having descended onto the battery assembly 500, clamps onto the battery assembly 500. Those skilled in the art will recognize that alternative mechanisms can be used to clamp the battery assembly 500 to the clamping device 308. As one possible solution, the battery assembly does not have a battery assembly clamping device 506, and the clamping device 308 is arranged to releasably clamp the battery assembly 500 to the clamping device 308. The battery assembly 500 also has a positive terminal and a negative terminal (in) located on its lower surface. Figure 5A (Not shown in the perspective view). The positive terminal 502 and negative terminal 504 on the upper surface of the battery assembly 500 and the positive terminal and negative terminal on the lower surface of the battery assembly 500 are arranged such that when another such battery assembly is adjacent to the battery assembly 500 (e.g., stacked on top of the battery assembly), the positive terminal 502 and negative terminal 504 on the upper surface of the lower battery assembly 500 form electrical contact with the corresponding positive terminal and negative terminal on the lower surface of the upper battery assembly.

[0037] The positive and negative terminals on the upper and lower surfaces of the battery assembly can be coplanar with the corresponding upper and lower surfaces, and / or can protrude / recess from the upper and lower surfaces. As an example, these terminals can be embodied as electrical contacts coplanar with the corresponding surfaces. As an example, the upper surface terminal can protrude while the corresponding lower surface terminal can be recessed, or vice versa, and both terminals on one surface can protrude while both terminals on the other surface are recessed, or one terminal on one surface can protrude while the other is recessed, and vice versa on the other surface. The positive and negative terminals can take on various shapes, such as square, rectangular, circular, columnar, cylindrical holes, prisms, prism-shaped recesses, etc. As another possible arrangement, the battery assembly can be arranged to wirelessly transmit power to adjacent battery assemblies, for example, via inductive charging, and therefore, in some cases, positive and negative terminals may not be present.

[0038] Figure 5BA second perspective view of the battery assembly 500 is shown. The battery assembly 500 has a positive terminal 508 and a negative terminal 510 located on the lower surface 512 of the battery assembly 500. A battery assembly clamping device 506 is also shown.

[0039] Figure 6 This is a perspective view of robot 202 and multiple stacks 602, 604, 606 of battery assemblies 500 stored in adjacent battery rows 134 of grid 100 (grid components are not shown to avoid visual obstruction). A battery assembly 500 releasably clamped to a clamping device 308 of robot 202 is also shown, such that if the clamping device 308 of robot 202 descends onto stack 602 (thus moving the battery assembly 500 within grid 100) and releases the battery assembly from the clamped state, then... Figure 6 The battery assembly 500, clamped to the clamping device 308, is then stacked on top of the stack 602. In this case, the positive and negative terminals on the underside of the released battery assembly 500 can then make electrical contact with those terminals on the upper surface of the topmost battery assembly 500 in the stack 602, thereby enabling the released battery assembly to be charged by one or more battery assemblies in the stack 602 and / or by the charger 136 located below the stack 602. The robot 202 can then traverse the grid 100 such that the robot is positioned above the stack 604 (in this example) and lowers the clamping device 308 to, for example, pick up the charged battery assembly from the stack 604.

[0040] When clamped to the clamping device 308, and / or if subsequently clamped against the body portion 300 of the robot 202, the battery assembly 500 is able to transfer electrical energy to the robot 300 to power the robot 300, thereby enabling the robot to move along the track of the storage grid 100 and to move the clamping device 308 of the robot 202 relative to its body portion 300. Electrical energy can be transferred via one or more of the following methods: the positive terminal 502 and negative terminal 504 of the battery assembly 500 and corresponding terminals on the clamping device 308 and / or body portion 300 of the robot 202; wirelessly (e.g., via inductive power transfer); and / or via one or more other electrical terminals (not shown) on the battery assembly 500 and corresponding terminals on the clamping device 308 and / or body portion 300 of the robot 202.

[0041] The robot 300 may have sensors for determining the amount of charge in the battery assembly it holds, so as to determine whether the battery assembly should be arranged in the battery bank for charging. Additionally or alternatively, the control system may monitor the work done by the robot 300 to determine when the battery assembly needs to be replaced. The robot 300 may have a second battery / battery assembly for powering the robot after its held battery assembly has been arranged in the battery bank and before a replacement battery assembly has been held in the robot 300. Additionally or alternatively, the robot 300 may have additional non-battery-based power supply devices, such as capacitors or supercapacitors, for powering the robot after its held battery assembly has been arranged in the battery bank and before a replacement battery assembly has been held in the robot 300.

[0042] although Figure 6 The method described herein has already been referenced to "cantilever" type robots, but it can also be applied to "internal cavity" type robots. Figure 7 This is a perspective view of the internal cavity type robot 702, showing its gripping device 704 and battery assembly 706 from below. This battery assembly is compatible with the components described above in Figure 5 and... Figure 6 The same as described above. Figure 7 The diagram also shows a belt 708 for raising and lowering the gripping device 704 relative to the body portion 710 of the robot.

[0043] Figure 8 This is a cross-sectional view of battery module 800, which can be compared with the above description. Figure 5A , Figure 5B and Figure 6 The battery assembly 500 is identical. The battery assembly has a battery management system (BMS) that is electrically connected to both the positive terminal 804 and the negative terminal 806 of the battery assembly 800. In this example, the positive terminal 804 and the negative terminal 806 protrude beyond the lower surface 805 of the battery assembly 800 and are recessed from the upper surface 807 of the battery assembly 800. The positive and negative terminals as seen from the upper surface 807 are electrically and physically continuous with their corresponding counterparts as seen from the lower surface 805. The lower surface 805 and the upper surface 807 are shown respectively in... Figure 8 The left and right sides are shown to illustrate that the concepts described herein are not necessarily only applicable to vertical stacking of battery modules, but can also be additionally or alternatively applied to horizontally “stacked” or rowed battery modules that are in contact with each other (or adjacent).

[0044] BMS 802 can be intelligent and is connected to battery 808 of battery assembly 800, which may include one or more battery cells, and BMS 802 is arranged to control the charging and / or discharging of the one or more battery cells. Battery 808 is arranged to power the robot, thereby enabling the robot to move along the track of the storage grid and to move the robot's gripper relative to its body portion.

[0045] BMS 802 can be configured to communicate with one or more of the following: the battery management system of other such battery components, the charger of the storage grid, and / or the control system of the storage grid (e.g., Figure 4 The control system (which can be a central control system) determines whether the battery assembly operates in a charging or discharging mode. Communication can be via antenna 810 or via other techniques known to those skilled in the art, such as optical or electrical communication. As one possible approach, each battery assembly may have additional terminals on its upper and lower surfaces to enable electrical communication with battery assemblies / chargers located in the same battery bank. The BMS 802 can be arranged to control the battery assembly to operate in the determined charging or discharging mode.

[0046] In charging mode, battery assembly 807 is arranged to receive charge via positive terminal 804 and negative terminal 806 to charge battery 808. BMS 802 can provide a direct electrical connection (or equivalent connection) between the positive terminal 804 of the battery assembly and the positive terminal of the battery 808, and similarly, can provide a direct electrical connection (or equivalent connection) between the negative terminal 806 of the battery assembly and the negative terminal of the battery 808. In this way, the voltage supplied across the positive terminal 804 and the negative terminal 806 is supplied entirely or substantially also across the terminals of battery 808. Similarly, in charging mode, the current flowing into the positive terminal 804 flows entirely or substantially entirely into battery 808.

[0047] In discharge mode, battery assembly 807 is arranged to supply charge via positive terminal 804 and negative terminal 806 to charge the battery of another battery assembly 800. BMS 802 can control battery assembly 807 such that a fixed voltage is presented between its positive terminal 804 and negative terminal 806. This voltage may differ from the voltage across the terminals of battery 808; for example, the voltage may be increased. BMS 802 may include drive circuitry to maintain this fixed voltage between its positive terminal 804 and negative electrical terminal 806. Furthermore, BMS 802 can control the voltage between its positive terminal 804 and negative terminal 806 to vary over time, for example, by gradually increasing it using a charge pump. Additionally or alternatively, BMS 802 can control battery assembly 807 such that a fixed current is supplied from its positive terminal 804, and BMS 802 may include drive circuitry to maintain this fixed current. In addition, the BMS 802 can control the supplied current to vary over time, for example by gradually increasing it.

[0048] In some examples, the BMS 802 can be configured to operate in a discharge mode with one or more of the following stages: bulk mode, in which the current supplied to the battery being charged is constant, but its voltage gradually increases; absorption mode, in which the voltage is constant and the supplied current decreases; float mode, in which the voltage is constant and the supplied current decreases or remains approximately constant; and equalization mode, in which the supplied voltage is higher and the current is lower. A four-stage charging cycle can be used (for the battery being charged) when the following sequence is employed: bulk, absorption, float, equalization.

[0049] Although the foregoing has been described with reference to a battery assembly having positive and negative terminals, those skilled in the art will recognize that these terms are relative to the battery assembly, and that if the positive terminal of the first battery assembly is electrically connected to the negative terminal (or grounded) of the second battery assembly, the positive terminal of the first battery assembly can be described as being at a negative voltage (or at ground voltage) relative to the positive terminal of the second battery assembly. They will also understand that the same applies, with appropriate modifications, to the negative terminal of the battery assembly.

[0050] Battery assembly stack and charger

[0051] Figure 9 This is a schematic diagram of the stack 900 of battery assembly 800 located on charger 902, where the battery assembly can be referenced above. Figure 8The battery assembly described is the same, and the charger therein can be used with... Figure 1 The charger indicated by mark 136 is the same. The stack 900 of battery assembly 800 is located in battery column 134 of grid 100. Figure 9 (Not shown in the image), and the charger 902 may be located inside or slightly outside / below the battery array 134 itself. The battery charger 902 has a positive terminal 904 and a negative terminal 906 for electrically connecting the charger 902 to any battery assembly 800 stacked thereon. The charger may be connected to an external power source 908, such as mains power, which may be alternating current (AC).

[0052] Charger 902 may be arranged to communicate with one or more of the following: a battery management system of any battery assembly stacked thereon, and / or a control system of the storage grid (e.g., Figure 4 The control system (which may be a central control system) is used to determine whether the battery assembly is operating in charging or discharging mode. Communication can be made via antenna 910, or via other technologies known to those skilled in the art, such as optical or electrical communication.

[0053] As from Figure 9 As can be seen, when multiple battery modules 800 are stacked on top of each other and on top of the charger 902, all positive terminals 804, 904 are electrically connected, and all negative terminals 806, 906 are also electrically connected, and the individual battery modules 800 and the charger 902 can be considered to be electrically connected in parallel. The combination of adjacent (in this case, physically contacting) positive terminals 804, 904 and physically contacting negative terminals 806, 906 effectively forms two power rails, through which charge can be transferred from the charger 902 and any one or more other battery modules 800 to any other battery module 800. Therefore, the battery module stack can effectively act as a large power source, enabling fast / surge charging of one (or more) battery modules in the stack.

[0054] As an example, a first battery module 800a may have a second battery module 800b positioned adjacent to it (in this case, stacked on top of it), and may be operable to transfer electrical energy to the second battery module 800b. Furthermore, the first battery module may be stacked on top of a third battery module 800c, and the first and third battery modules may be arranged to cooperate in transferring electrical energy from the first battery module 800a and the third battery module 800c to the second battery module 800b.

[0055] although Figure 9The stack 900 of battery components 800 stacked on top of charger 902 has been described, but even in the absence of charger 902, one or more battery components 800 can transfer their electrical energy (charge) to one or more other battery components 800.

[0056] When the stack 900 of battery modules 800 is stored in the battery column 134 with charger 900, the bottommost battery module 800 is likely to be stored in the stack 900 for the longest time (considering that battery modules are added and removed via the top of the grid), and therefore the bottommost battery module is charged by charger 902 for the longest time, thus potentially retaining the most charge. The same applies to battery modules stacked on top of the bottommost battery module, only decreasing in that order. Therefore, it is advantageous to transfer electrical energy from lower battery modules to higher battery modules (i.e., from battery modules positioned further away from the grid 100 (or top) to battery modules positioned closer to the grid 100 (or top).

[0057] Furthermore, utilizing the charging process that transfers electrical energy from lower battery modules 800 to higher battery modules, and considering that the lower battery modules 800 will have more time to receive charge from the charger 902 and accumulate it in their own cells (for charging), fast charging of the higher battery modules 800 can be primarily (or entirely) provided by one or more lower battery modules 800 without requiring the charger 900 to be configured to perform fast charging. Therefore, the requirements for the charger 902 are lower than if the charger were to perform charging on all the upper battery modules 800, allowing the charger 902 to have lower specifications than it would otherwise require, such as lower power and / or thermal ratings. This avoids the need for a charger configured for surge charging. As one possible solution, the charger 902 could include a charge pump / trickle charger.

[0058] Battery charging

[0059] Figure 10 A flowchart illustrating the method steps that can be performed according to this disclosure is shown. In step S1005, the battery assembly is clamped to the gripping device of the robot. Step S1005 occurs... Figure 10This occurs sometime before subsequent steps. As an example, if the battery assembly is arranged to transfer electrical energy to the robot via a gripping device, step S1005 can occur during the following process: the robot picks up the fully charged battery assembly (by gripping it to the gripping device), then carries the battery assembly while performing normal mesh operations (lifting, transporting, and lowering the container / battery assembly) until the battery assembly is sufficiently depleted and needs recharging. Alternatively, the battery assembly can be gripped to the body portion during normal operation and only held by the gripping device when it is about to be lowered onto (or lifted from) the battery array.

[0060] In step S1010, the robot moves the battery assembly within the grid by lowering the gripping device and the gripped battery assembly into the battery row, and then in step S1015, the battery assembly is released onto the stack of other battery assemblies.

[0061] In step S1020, communication related to charging the battery assembly is performed. This can be initiated by the BMS of the most recently lowered battery assembly, for example, by sending radio or NFC communication after determining that the battery assembly has been lowered onto the battery bank. The BMS can determine whether a battery assembly has been lowered into the battery bank, for example, by detecting the voltage between the positive and negative terminals of the battery assembly. Additionally or alternatively, sensors can be used for determination, or a robot can notify the battery assembly, for example, via radio that it has been released. Communication can be with the BMSs of other battery assemblies in the battery bank, with the charger, and / or with the control system of the storage grid. Communication can indicate that the battery assembly has just been lowered onto the stack, and / or indicate the amount of battery charge held by the battery assembly (e.g., expressed as a percentage charge), and can initiate a negotiation process between the BMS of the most recently lowered battery assembly and the BMSs of one or more other battery assemblies in the battery bank to determine which battery assembly in the battery bank should be charged first. As mentioned above, the most recently lowered battery assembly may be the one most in need of charging, so the default practice may be to always charge that battery assembly first.

[0062] After determining that the recently degraded battery module needs charging, the BMSs of one or more other battery modules in the battery bank coordinate (or self-coordinate) to provide charge to the newly degraded module, for example, by agreeing via communication and setting the voltage between its positive and negative terminals to be higher than the voltage of the battery in the newly degraded module. Additionally or alternatively, the BMSs may coordinate (or self-coordinate) such that they each provide a constant current output (which may be the same for each discharging battery module). This coordination may include sending communications containing parameters. For example, charging voltage and / or current, as well as the time points or thresholds at which they change, may be transmitted in the communications for the receiving BMS to use in configuring itself.

[0063] Step S1020 can be intentionally extended beyond the time required for communication, determining the battery component to be charged, and coordinating the BMS. This intentional extension is to allow the voltage between the positive and negative terminals of the battery component receiving the charge to be stabilized.

[0064] In step S1025, electrical energy can be transferred from one or more other battery modules in the battery bank to the battery of the battery module that has just been de-energized, and this can be done in a manner with constant voltage and / or constant current.

[0065] Additional or alternative grounds can communicate with the charger and can set its output voltage or current to charge the batteries in the battery pack that has just been de-charged.

[0066] Once the battery pack being charged in step S1025 has been charged to the required level, or if the robot needs a fully charged battery beforehand, the following steps are performed in advance: the robot itself moves above the battery bank, lowers its gripping device, and grips the battery pack in step S1030. Then, in step S1035, the battery pack is raised, and in step S1040, the battery pack is used to power the robot, either directly via the gripping device or by clamping the battery pack to the robot's body, for example, by bringing the positive and negative terminals of the battery pack into contact with the corresponding terminals on the robot's body.

[0067] although Figure 10 The flowchart illustrates one approach that the device described herein can take, but it is far from the only approach, and within the bounds of common sense... Figure 10 Any or all steps in the method other than step S1025 may be omitted, and / or these steps may be performed in a different order.

[0068] Figure 11A flowchart illustrating the method steps that can be performed according to this disclosure is shown. In step S1105, the BMS of a battery module located in a battery bank and having partially charged batteries receives a communication instructing the battery module to operate in a discharge mode to transfer charge to another battery module in the battery bank. This communication may inform the BMS how to configure itself for discharging; for example, the discharge voltage and / or current, as well as the time points or thresholds at which changes may occur, may be transmitted in the communication. Additionally or alternatively, the communication may be part of a negotiation between the BMS and one or more other BMSs and / or with the charger to determine discharge parameters. In step S1110, the BMS of the battery module that received the communication can configure its battery module for discharging based on the parameters received in the communication, and subsequently transfer electrical energy to other battery modules via the battery module's terminals, thereby charging the other battery modules.

[0069] The robot can be manipulated to lift, reposition / rearrange, and lower battery modules to retrieve the "most suitable" battery from the grid. As an example, the control system can determine that a battery module located in the middle of a stack of battery modules in a battery row is fully charged and is the optimal battery module for retrieval and use. Therefore, the robot can manipulate to lower its gripper, retrieve and remove other battery modules located on top of the identified battery module, thus enabling the retrieval and use of the identified battery module.

[0070] Although the foregoing description refers to a vertically stacked battery assembly (possibly on top of the charger), those skilled in the art will understand that the concepts described herein can also be applied to other configurations, such as those where the battery assemblies / chargers are positioned adjacent to each other in the horizontal direction (horizontal stacking, not the vertical stacking described above), and where the robot can be manipulated to move along the grid. Similarly, although the foregoing description pertains to a grid with tracks on top and accessible from the top, the methods described herein can also be applied to grids with tracks below and accessible from the bottom (inverted stacking method).

[0071] This paper describes a method for charging a first battery assembly arranged to power a robot, enabling the robot to move along a track of a storage grid and for the robot's gripper to move relative to the robot's body. This method is achieved by transferring electrical energy from a second battery assembly to the first battery assembly.

[0072] It should be understood that the above description is intended to be illustrative and not restrictive. Many other implementations will be apparent to those skilled in the art upon reading and understanding the above description. Although this disclosure has been described with reference to specific exemplary implementations, it should be recognized that this disclosure is not limited to the described implementations but can be practiced with modifications and alterations falling within the spirit and scope of the appended claims. Therefore, the specification and drawings are to be regarded in an illustrative sense and not a restrictive sense. Consequently, the scope of this disclosure should be determined by reference to the appended claims and the full scope of their equivalents.

Claims

1. A method for charging a first battery assembly, the first battery assembly being arranged to power a robot, thereby enabling the robot to move along a track of a storage grid and enabling the gripping device of the robot to move relative to the body portion of the robot, the first battery assembly being adjacent to a second battery assembly in the storage grid, the method comprising: Electrical energy is transferred from the second battery module to the first battery module.

2. The method according to claim 1, wherein, During the transfer of electrical energy from the second battery assembly to the first battery assembly, the second battery assembly is positioned further away from the orbit of the storage grid than the first battery assembly.

3. The method according to claim 2, wherein, During the transmission of electrical energy, the first battery assembly is stacked on top of the second battery assembly.

4. The method according to any one of the preceding claims further comprises: The first battery assembly is clamped to the clamping device; as well as The clamping device is moved relative to the body portion, thereby moving the first battery assembly to be adjacent to the second battery assembly.

5. The method according to any one of the preceding claims, wherein, The first battery assembly and the second battery assembly are electrically connected in parallel when they are adjacent to each other. Optionally, the second battery assembly is electrically connected in parallel with one or more other battery assemblies and / or a charger, and is stacked on top of the one or more other battery assemblies and / or the charger, and the method further includes: transferring electrical energy from the one or more other battery assemblies and / or the charger to the first battery assembly.

6. The method according to any one of the preceding claims, further comprising: The decision to operate the second battery assembly in discharge mode is based on communication with one or more of the following: The battery management system of the first battery assembly; One or more battery management systems for other battery components that are electrically connected in parallel with the second battery component; The charger for the storage grid is electrically connected in parallel with the second battery assembly; and / or The control system of the storage grid.

7. The method according to any one of the preceding claims, further comprising: The second battery module supplies one or both of a constant current and a constant voltage to the first battery module.

8. A battery assembly for powering a robot, thereby enabling the robot to move along a track of a storage grid and enabling the robot's gripping device to move relative to the robot's body portion, the battery assembly being arranged as follows: When the battery assembly is positioned against the robot, the battery assembly transmits electrical energy to the robot via the clamping device and / or the body portion; The battery assembly is releasably clamped to the clamping device, and thus the battery assembly is moved within the storage grid by the robot; This allows electrical energy to be transferred between the battery modules when the second type of battery module is positioned adjacent to the battery module.

9. The battery assembly of claim 8 is further arranged such that, when the battery assembly is stacked on a third such battery assembly, electrical energy can be transferred from the battery assembly and the third battery assembly to the second battery assembly.

10. The battery assembly according to claim 9, wherein the battery assembly comprises: Positive and negative electrical terminals located on the upper side of the battery assembly are arranged such that, when the second type of battery assembly is stacked on top of the battery assembly, these electrical terminals contact corresponding positive and negative electrical terminals on the lower side of the second type of battery assembly. Positive and negative electrical terminals are located on the underside of the battery assembly, and these electrical terminals are arranged such that when the battery assembly is stacked on top of the third type of battery assembly, these electrical terminals contact the corresponding positive and negative electrical terminals on the upper side of the third type of battery assembly.

11. The battery assembly of claim 10, wherein, One or both of the following are true: A) One of the positive terminals of the battery assembly protrudes beyond the corresponding side of the battery assembly, and the other positive terminal of the battery assembly is recessed relative to the corresponding side of the battery assembly. B) One of the negative terminals of the battery assembly protrudes beyond the corresponding side of the battery assembly, and the other negative terminal of the battery assembly is recessed relative to the corresponding side of the battery assembly.

12. The battery assembly according to any one of claims 8 to 11, further comprising a battery management system, the battery management system being arranged as follows: It communicates with one or more of the battery management systems of other such battery components, the charger of the storage grid, and the control system of the storage grid to determine whether the battery component operates in a charging mode or a discharging mode; and Control the battery assembly to operate in a determined charging or discharging mode.

13. The battery assembly according to claim 12, wherein, The battery management system is configured to charge the second battery component with one or both of a constant current and a constant voltage when the battery component is operating in a discharge mode.

14. A system including a storage grid, the storage grid comprising a charger arranged such that electrical energy can be transferred between the charger and the battery assembly when a battery assembly according to any one of claims 8 to 13 is stacked on the charger.

15. A computer-readable medium carrying computer-executable instructions, which, when executed by one or more processors, cause the method according to any one of claims 1 to 7 to be performed.

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