Assembly and method for battery maintenance

Abstract

To provide an assembly for battery maintenance.SOLUTION: An assembly is provided that may include a battery 202, and an end cap 204 mechanically and electrically coupled to the battery. The end cap may contain an electrical connector 218 with at least one electric cable 222 configured to supply current to at least one operating system electrically coupled to the battery. The end cap may also contain at least one electronic board coupled to the battery, and may be configured to be detached from the battery to provide access to the electrical connector and the electronic board.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The described subject matter relates to assemblies and methods for providing servicing to a battery.

Background Art

[0002] Vehicles are used for both passenger transportation and / or cargo transportation. Vehicles can be a single vehicle system or multiple vehicle systems. There are numerous power systems for powering a vehicle, including internal combustion engines, batteries, hybrid systems, hydraulic systems, and the like.

[0003] When a vehicle system utilizes a high - power battery, significant caution may be required to prevent injury to maintenance workers due to electric shock, electrocution, etc. Unlike an engine where operation can be stopped, a battery may have a voltage present while the vehicle system is stopped. As a result, maintenance personnel must take additional precautions to protect themselves from the dangers of voltage and arcing during battery installation, inspection, removal, replacement, etc. As a result, a large amount of personal protective equipment (PPE) may be required to handle high - voltage batteries. PPE may include rubber gloves, full - body arc flash suits or clothing, along with typical safety glasses, safety wear, etc. They are bulky, difficult to store, and expensive. Furthermore, changing into and out of PPE to work on the battery is time - consuming and inefficient.

[0004] Additional safety clothing typically causes inconvenience at railway stations. In particular, it is not practical to store equipment for all maintenance workers, and the time required to put on and remove such equipment results in significant inefficiencies and delays when passengers and / or cargo are on schedule.

Summary of the Invention

[0005] In one or more embodiments, an assembly is provided which may include a battery and an end cap mechanically and electrically coupled to the battery. The end cap may include an electrical connector having at least one electrical cable configured to supply current to at least one operating system electrically coupled to the battery. The end cap may also include at least one electronic circuit board coupled to the battery and may be configured to be removable from the battery to provide access to the electrical connector and the electronic circuit board.

[0006] In one or more embodiments, an assembly is provided which may include a battery and an end cap mechanically and electrically coupled to the battery. The end cap may include a first section which includes an electrical connector having at least one electrical cable configured to supply current to at least one operating system electrically coupled to the battery. The end cap may also include a second section which includes at least one electronic circuit board coupled to the battery. The assembly may additionally include a service disconnector electrically coupled to the circuit including the battery and the electrical connector. The service disconnector may be configured to provide an electrical connection between the battery and the electrical connector in the connected position and to disconnect the battery and the electrical connector in the disconnected position. The assembly may also include a cover which may be coupled to the first section of the end cap to enclose the electrical connector in the first section. The cover may also include a tab portion positioned adjacent to the service disconnector such that the service disconnector engages with the tab portion when the service disconnector is in the connected position, thereby preventing the cover from moving.

[0007] In one or more embodiments, an assembly is provided which may include a battery and an end cap mechanically and electrically coupled to the battery. The end cap may include a first section including an electrical connector having at least one electrical cable configured to supply current to at least one operating system electrically coupled to the battery. The end cap may also include a second section including at least one electronic circuit board coupled to the battery. The assembly may also include a tag coupled within the first section of the end cap and configured to move from an unlocked position to a locked position. In the locked position, the tag may cover an electrical port that accepts the electrical connector.

[0008] The subject matter of the present invention may be understood by referring to the accompanying drawings and reading the following description of non-limiting embodiments. [Brief explanation of the drawing]

[0009] [Figure 1] A schematic block diagram of the vehicle system is shown. [Figure 2] This shows a front perspective view of the disassembled and assembled energy storage assembly. [Figure 3] A front plan view of the energy storage assembly is shown. [Figure 4] A front plan view of the energy storage assembly is shown. [Figure 5] This shows a rearward perspective view of the disassembled and assembled energy storage assembly. [Figure 6] This shows a front perspective view of the disassembled and assembled energy storage assembly. [Figure 7] This shows a rearward perspective view of the disassembled and assembled energy storage assembly. [Figure 8] This shows a front perspective view of the disassembled and assembled energy storage assembly. [Figure 9] This shows a rearward perspective view of the disassembled and assembled energy storage assembly. [Figure 10] This shows a front plan view of a portion of the energy storage assembly. [Figure 11] This shows a front plan view of a portion of the energy storage assembly. [Figure 12] A forward perspective view of the energy storage assembly is shown. [Figure 13] A forward perspective view of the energy storage assembly is shown. [Figure 14] A flow block diagram of how to maintain an energy storage assembly is shown. [Modes for carrying out the invention]

[0010] Embodiments of the subject matter described herein relate to energy storage assemblies configured to facilitate on-site maintenance of vehicle system batteries, thereby reducing the PPE required to provide maintenance. In one embodiment, the battery to be maintained is a high-power or high-voltage battery (e.g., having a storage capacity of at least 200 volts). Alternatively, the battery to be maintained may be a battery with a storage capacity of less than 200 volts. The battery assembly utilizes a removable end cap, which includes a cover housing electrical cables and coupled to a disconnector. This switch can operate to interrupt the current supplied from the battery to the electrical cables by removing the cover to access the electrical cables. Furthermore, spacing is provided for coupling a clamp ammeter to the electrical cables, while a magnet is provided on the cover and / or end cap adjacent to the electrical cables for a gauss meter. In this way, a live-dead-live test may be easily performed before contact with the electrical cables. The battery assembly may also include a compartment which may include a removable panel that may be configured to allow access to electronic circuit boards such as a computer processing unit (CPU) card, a wireless card, etc., without removing the end cap. In this way, frequently failing electrical components can be accessed without exposing maintenance workers to electrical cables that may contain high voltage. Furthermore, a lockout / tagout (LOTO) function is also provided to allow maintenance workers to leave the premises during maintenance without fear of another worker attempting to replug the electrical cables before the maintenance is complete.

[0011] Figure 1 shows a schematic diagram of an example of a vehicle system 100 including assembly 102. The vehicle system may be configured to travel along a route 104 from a starting point or origin to a destination or arrival point. The vehicle system includes a propulsion-generating vehicle 108 and a non-propulsion-generating vehicle 110 that are mechanically interconnected with each other to move together along the route. The vehicle system may include at least one propulsion-generating vehicle and optionally one or more non-propulsion-generating vehicles. Alternatively, the vehicle system may consist of only a single propulsion-generating vehicle.

[0012] A propulsion-generating vehicle may generate a traction force to propel (e.g., pull or push) the vehicle system along a route. The propulsion-generating vehicle includes a propulsion subsystem such as an engine and one or more traction motors that operate to generate a traction force for propelling the vehicle system. The propulsion-generating vehicle also includes a braking system that generates a braking force to slow or stop the movement of the vehicle system. While one propulsion-generating vehicle and one non-propulsion-generating vehicle are shown in Figure 1, the vehicle system may include multiple propulsion-generating vehicles and / or multiple non-propulsion-generating vehicles. In an alternative embodiment, the vehicle system includes only propulsion-generating vehicles, thereby not coupling the propulsion-generating vehicles with non-propulsion-generating vehicles or other types of vehicles. In yet another embodiment, vehicles within the vehicle system are logically or virtually coupled to one another, but not mechanically. The vehicle system may include rail vehicles, water vehicles or fleets of water vehicles, airplanes or fleets of aircraft, off-road vehicles, tractor-trailers, construction vehicles, mining vehicles, automobiles, trucks, combines, tractors, etc.

[0013] In the example shown in Figure 1, each vehicle in the vehicle system includes a plurality of wheels 120 that engage with the path and at least one axle 122 that connects the left and right wheels together (only the left wheel is shown in Figure 1). Optionally, the wheels and axles are mounted on one or more tracks or bogie trucks 118. Optionally, the tracks may be fixed-axle tracks, in which case the wheels are rotatably fixed to the axles, and so the left wheel rotates at the same speed, amount, and time as the right wheel. In one embodiment, the vehicle system may not include axles, as in some mining vehicles, electric vehicles, etc.

[0014] The assembly may further include an energy storage device 124 used to supply power to the operating systems of the vehicle system. The energy storage device may include one or more batteries or battery cells. For example, the energy storage device may be a high-voltage battery that operates or has a storage capacity of 200 volts or more and 400 volts or less. Alternatively, the energy storage device may store more than 400 volts or less than 200 volts. The energy storage device may be a main power source for propelling the vehicle system, part of a hybrid power source for propelling the vehicle system, or an auxiliary power source for supplying power to operating systems other than those for propelling the vehicle system. The operating systems may include a propulsion system, a braking system, a lighting system, a communication system, a fluid level system, a traction control system, and the like.

[0015] Figures 2 to 9 provide various diagrams of the energy storage assembly 200. In one example, the energy storage assembly is a high-voltage battery for powering a vehicle system, including the vehicle system in Figure 1. As used herein, the high-voltage battery includes a battery that generates at least 200 volts and may include batteries that generate 200 to 400 volts, 600 to 3000 volts, and a DC battery assembly. Furthermore, in other examples, the energy storage assembly may include one or more fuel cells, supercapacitors, flywheels, etc.

[0016] The energy storage assembly 200 includes one or more batteries 202 and end caps 204. The battery may be composed of a number of individual batteries or battery cells 206a, 206b coupled to each other. The coupled batteries may be coupled in series, parallel, a combination of series and parallel, etc. In another example, the battery has only a single battery cell. The battery also includes an electrical connector port 208 for receiving an electrical connector. The electrical connector port includes individual ports that can include live wire ports, ground ports, etc. for providing an electrical connection.

[0017] The battery may also include a communication port 210 for electronically and / or electrically coupling to at least one processor on the circuit board of the end cap. The communication port is a wiring connection port, a USB port, an Ethernet port, etc. The communication port provides a communication path for receiving data and information regarding the battery.

[0018] The end cap includes a housing 212 that is mechanically and electrically coupled to the battery and has a first section 214 and a second section 216 adjacent or near the first section. In one example, the housing is a one-piece structure, whereby the entire end cap can be removed. Alternatively, the first section and the second section can be removably coupled to each other, whereby the first section and the second section can be removed from the battery simultaneously and removed, or optionally, removed from the battery separately from each other and removed. In this way, the electrical components included in each section can be maintained individually without the need to remove the other section.

[0019] In an exemplary embodiment, the first section of the end cap includes an electrical connector 218 that is electrically coupled to the electrical connector port of the battery. The electrical connector may include a head 220, a first electrical cable 222, and a second electrical cable 224. At least one of the first electrical cable or the second electrical cable is configured to supply current to at least one operating system electrically coupled to the battery. In one example, one of the first electrical cable or the second electrical cable may be grounded.

[0020] The first section may include a cavity 226 for receiving the head of the electrical connector, a first channel 228 for receiving the first electrical cable, and a second channel 230 for receiving the second electrical cable. In one example, each of the first channel and the second channel is an arcuate channel shaped to fit and receive the first electrical cable and the second electrical cable, respectively. By providing the cavity, the first channel and the second channel facilitate preventing miswiring by aligning the electrical connector within the first section. The first electrical cable and the second electrical cable may extend within the cavity before engaging the first channel and the second channel, respectively. In this way, the cavity is sized and shaped to allow the clamp of a clamp-on ammeter to be placed around each cable without the user having to physically contact either electrical cable. As a result, a live-dead test can be performed on the electrical connector without having to physically contact the electrical connector. The live-dead test is a test in which test equipment such as a clamp-on ammeter, a gauss meter, a voltmeter, etc. is first tested to show that the test equipment is operating properly on a live outlet or power source, and then to determine whether current is still being conducted through a cable, outlet, etc. that should be disconnected. If the cable, outlet, etc. is disconnected, no readings are provided, while if it is not properly disconnected or operating, a reading representing the current present is detected.

[0021] Optionally, a magnet 230 may be provided in association with the first compartment to assist in live-to-dead-to-live testing. In the exemplary embodiments shown in Figures 2 to 5, the magnet may be located on the upper end caps of the first and second cables. In this way, the magnet can be used to indicate to the maintenance worker that the gaussmeter is operational before the gaussmeter is used to determine whether current may be conducted through either the first or second electrical cable. Alternatively, the magnet may be located within the second compartment, within the cover of the first compartment, etc. In yet another example, a current source with a switch may be used in association with the magnet.

[0022] The first compartment may also include a cover 232 (removed in Figures 3 and 4) which may be matably received within a cavity to house or enclose an electrical connector inside the first compartment of the end cap. In one example, the cover may be made of a transparent material. In another example, the cover may be made of a material that does not affect the magnetic field generated as a result of the current in either the first or second electrical cable. In this way, the gaussmeter may detect the current in either the first or second electrical cable without having to physically contact the electrical cable. In another embodiment, the cover may include an opening 233 that allows the clamp of a clamp ammeter to be positioned around one of the electrical cables. In each example, the cover provides a structure that allows a maintenance worker to perform live-to-dead-to-live testing without having to perform a test that requires physical contact with the electrical connector.

[0023] In one example, the cover extends from a first end 234 adjacent to the head of the electrical connector to a second end 236 on the edge of the end cap. At the second end, the cover may extend into a first compartment behind the service disconnector 238, and then upward into a tab portion 240 which may be behind the service disconnector. In this way, the cover cannot be removed without removing the service disconnector. In particular, the service disconnector includes the electrical connection of the circuit between the battery and the electrical connector. As a result, when the service disconnector is removed, the circuit is interrupted, thereby preventing current from being conducted to or through the first or second electrical cable. This also ensures that the power to the electrical cable is cut off and that no individual providing maintenance on the electrical connector will physically interact with the electrical connector unless a test can be provided to confirm that the interruption has occurred. In this way, the only protective clothing required to repair the electrical connector is safety glasses and work gloves, which are typically found and readily available in a maintenance facility.

[0024] On the other hand, the second compartment receives the first substrate 244 and the second substrate 246. Optionally, the second compartment receives only one substrate, but in other exemplary embodiments, the second compartment receives three or more substrates. In one example, each substrate may be a circuit board containing electronic components for monitoring and managing the battery and for communicating battery-related data and information. In one example, one of the first substrate and / or the second substrate may be a computer processing unit (CPU) card. Optionally, the first substrate and the second substrate may be electrically coupled to each other. In one example, the first substrate and / or the second substrate may include a wired communication connection 248, while in an alternative example, the first substrate and / or the second substrate may include a wireless communication connection 250.

[0025] Figures 6–9 show that the first and second substrates may be fixed to a panel 252 which may be coupled within a second compartment. The panel may be bolted, screwed, provided with removable adhesive, or friction-fitted, etc., to be removablely fixed within the second compartment. Furthermore, the panel may include slotted sections that allow the first and / or second substrates to slide into slotted sections in order to removely fix the first and / or second substrates to the panel. In other exemplary embodiments, the first and / or second substrates may be coupled and fixed to the panel via fasteners, connectors, removable adhesive, Velcro, friction-fitted, etc. To provide maintenance of the first and second substrates, fixing the first and second substrates to a panel which may be removable from the second compartment requires only removal of the panel, without the need to expose the battery or the electrical connectors of the first connector. In particular, the electronics of the CPU card are often the reason for needing repair. By isolating the CPU card from electrical components such as electrical connectors that may have dangerous voltages requiring reinforced protective clothing, maintenance personnel can check the CPU without needing to wear reinforced protective clothing, as they will not be exposed to the electrical connectors.

[0026] Figures 10–13 illustrate additional safety mechanisms for an exemplary energy storage assembly. In the exemplary embodiment, the energy storage assembly may include one or more high-power batteries, fuel cells, supercapacitors, flywheels, etc. In this exemplary embodiment, the energy storage assembly utilizes a battery, which is not shown, but instead only an end cap 704 is shown, and more specifically only a first compartment 714 of the end cap is shown. As a result, as shown in more detail than in Figures 2–9, the first compartment of the end cap includes a socket 718a for an electrical connector 718b that electrically couples to the electrical connector port of the battery. The socket may be provided to align the electrical connector for acceptance by the battery. In particular, the socket may include a coupling portion 719a configured to receive an electrical head 720, and a flange 719b extending away from the coupling portion and engaging with the end wall of the first compartment. The electrical connector may include a head, a first electrical cable 722, and a second electrical cable (not shown). In this embodiment, as in the embodiments of Figures 2 to 9, the first compartment may include a cavity 726 for receiving the head of an electrical connector, a first channel 728 for receiving a first electrical cable, and a second channel 730 for receiving a second electrical cable. In the exemplary embodiments shown in Figures 10 to 13, the cover and service disconnector are not shown, but are for illustrative purposes only.

[0027] Figures 10–13 also show a lockout-tagout (LOTO) assembly 754. The LOTO assembly in this embodiment includes a cover 756 having a first section 758 pivotally coupled to a second section 760. The second section 760 may be pivotally coupled to a third section 762. In one example, the first section, the second section, and the third section may be hinged to each other.

[0028] The first section may be configured to be coupled to a socket. In one example, the first section may be linear or have an opening so that it surrounds, engages with, and is secured to the flange of the socket. In this way, the first section of the cover provides a base for the second and third sections of the cover.

[0029] In the first position (Figure 10), the second and third sections are located within a cavity in the stowed position. In particular, the second section extends away from the first section and, in one example, may be parallel to the first section. The third section may include a bend 764 for providing a first portion 766 extending from the second section and a second portion 768 extending from the bend. As a result, the second portion engages with the second section and extends along the second section when the second and third sections are in the stowed position. In one example, a restraining fastener 769, such as a bolt, screw, or rivet, may extend through the second and third sections into the first compartment and be provided to hold the second and third sections in place in the stowed position.

[0030] In the second position (Figure 11), the electrical connector may be removed, leaving only the socket in the cavity. In the second position, i.e., the locked position, the second and third sections extend over the opening provided by the socket. In the locked position, the restraining fastener can fix the third section in the cavity of the first compartment. In this way, the cover may be fixed in the locked position, in which case the electrical connector cannot be inserted into the socket because the cover prevents or inhibits insertion.

[0031] As shown in Figures 12 and 13, the cover may also include a flange 770 having an opening 772 that extends from the socket and aligns with one or more openings in the first compartment. In this way, if a person performing maintenance on the electrical connector has to leave the work area before reinserting the electrical connector into the socket, that person can secure the lock 774 through the aligned opening. This prevents any untrained person providing maintenance on the high-voltage battery from attempting to connect the electrical connector and ensures that only a maintenance worker with access to the lock key can reinsert the electrical connector into the socket.

[0032] Figure 14 shows a method 1400 for providing maintenance for a high-voltage battery. In one example, the energy storage assemblies shown in Figures 2 to 9 are provided for maintenance, and in another example, the energy storage assemblies shown in Figures 10 to 13 may be provided. During maintenance, when following this method, maintenance personnel only need to wear standard safety glasses and gloves in the maintenance area.

[0033] In 1402, a panel having at least one circuit board may be removed from the battery end cap. In one example, the panel may be bolted to a second compartment of the end cap, which also includes a first compartment for enclosing electrical connectors. In this example, at least one circuit board may be fixed to the panel so that when the bolts are removed, at least one circuit board may be removed from the panel. In one example, at least one circuit board is slid out of the panel for inspection. In one embodiment, at least one circuit board may be a CPU card. By providing two separate compartments, including a first compartment having electrical connectors which may be fully enclosed, it may be unnecessary to wear additional PPE.

[0034] In 1404, a determination may be made as to whether at least one circuit board may be malfunctioning. Maintenance personnel may confirm that at least one circuit board has a malfunctioning component, such as a rectifier, resistor, capacitor, transformer, or transistor. If at least one circuit board is malfunctioning in 1404, then in 1406, at least one circuit board may be repaired or replaced. In one example, a new CPU card may be fixed to the panel, or the panel may simply be reinserted into the second compartment and bolted in place. In another example, only the malfunctioning component may be replaced before fixing at least one circuit board to the panel. In yet another example, components may be replaced with other components, such as replacing a wired communication connection with a wireless connection. In each case, at least one circuit board can be repaired or replaced without the need for special PPE.

[0035] In 1404, if at least one circuit board is not malfunctioning, in 1408, the service disconnector may be removed from the first compartment. After it is determined that at least one circuit board is not malfunctioning, the panel may be reinserted and secured within the end cap, and the electrical connector may be inspected for malfunction. The first step may be to remove the service disconnector to interrupt the circuit between the battery and the electrical connector. In this way, the electrical connector remains housed within the end cap until no more current is conducted to it. Therefore, the maintenance worker does not need to handle the electrical connector until it is no longer receiving power.

[0036] In 1410, optionally, a live-dead-line test may be performed by a maintenance worker to determine whether an electrical connector containing a cable is still conducting current through the cable. In one example, the worker has a gaussmeter and moves the probe across a magnet inside the housing or cover of the first compartment. In this way, the worker confirms that the gaussmeter is working and functioning. The gaussmeter may then be moved across each electrical cable while the cover remains in place. In one example, the cover may be made of a material that may be transparent to a magnetic field. In another example, the cover includes an opening that provides access to each electrical cable so that the gaussmeter can be moved outside the cable. In yet another example, the worker utilizes a clamp current detector and, as a result of the size and shape of the cavity, inserts the clamp around the cable through the opening in the cover, or removes the cover and inserts the clamp around each cable.

[0037] In 1410, if it is determined that current is still flowing through at least one of the cables, in 1412, the end cap may be removed from the battery. If current is still flowing through the cables, the entire end cap may be removed from the battery to physically disconnect the electrical connector from the battery. As a result, if the service disconnector does not result in the cessation of current conduction to the electrical connector, a backup disconnector is provided. In this way, the worker can both use the service disconnector to cut off power to the electrical connector and use a live-dead test to verify that no power is being supplied before the worker has to physically touch the electrical connector. In most cases, it is not even necessary to remove the cover to do so, and access to the electrical connector is prevented until it is confirmed that no power is being supplied to the electrical connector. As a result, the worker only needs safety glasses to provide maintenance on the electrical connector.

[0038] If no current is detected in 1410, maintenance can be provided to the electrical connector in 1414. This may include replacing the electrical connector or the cable. If the electrical connector needs to be replaced, and after the electrical connector is removed in 1416, if the worker needs to leave the battery, the worker can cover the socket of the electrical connector with the LOTO assembly and lock the cover of the LOTO assembly. In this way, another person who is not intended to have access to the electrical connector or socket cannot accidentally attempt to connect the electrical connector to the socket.

[0039] Overall, due to the additional safety features provided herein, maintenance personnel may perform battery maintenance using limited PPE. By providing access, opportunities for live-to-dead-to-live testing, service disconnectors, etc., a minimum amount of PPE may be required, saving time and space.

[0040] In one or more embodiments, an assembly is provided which may include a battery and an end cap mechanically and electrically coupled to the battery. The end cap may include an electrical connector having at least one electrical cable configured to supply current to at least one operating system electrically coupled to the battery. The end cap may also include at least one electronic circuit board coupled to the battery and may be configured to be removable from the battery to provide access to the electrical connector and the electronic circuit board.

[0041] Optionally, the service disconnector may be electrically coupled to a circuit including a battery and an electrical connector. The service disconnector may be configured to provide an electrical connection between the battery and the electrical connector in the connected position and to disconnect the battery and the electrical connector in the disconnected position. In one embodiment, the service disconnector may be configured to be fixed within an end cap in the connected position, and the service disconnector may be configured to be detachable from the end cap in the disconnected position. In another embodiment, the energy storage assembly may also include a cover configured to be coupled to an end cap and to house an electrical connector within the end cap. In one example, the cover may be coupled to the service disconnector to prevent the cover from being removed when the service disconnector is in the connected position. In another example, the cover may include an opening adjacent to at least one electrical cable to allow access to at least one electrical cable. Alternatively, the cover may include a magnet disposed therein. In another example, the end cap may include a magnet disposed therein.

[0042] Optionally, the end cap may include a cavity configured to receive an electrical connector. The cavity may also be configured to accommodate the clamp of a clamp sensor around at least one electrical cable. In one embodiment, the cavity may include at least one channel configured to receive at least one electrical cable. In another embodiment, at least one electronic board may include at least one of one or more processors or transponders. In one example, at least one electronic board may include a first electronic board containing one or more processors and a second electronic board containing a transponder and electrically coupled to the first electronic board. In another example, at least one electronic board may be a wireless transmission card. In one example, the wireless transmission card may be a circuit board containing circuitry for coupling to a WiFi or other wireless network. In one example, the wireless transmission card may be called a wireless internet card. Alternatively, at least one electronic board may be a computer processing unit card.

[0043] Optionally, at least one electronic circuit board may be electrically coupled to the battery. In one embodiment, at least one electronic circuit board may be wirelessly coupled to the battery. In one example, the end cap may include a first section housing an electrical connector and a second section housing at least one electronic circuit board. The second section may be configured to provide access to the at least one electronic circuit board without removing the end cap from the battery. In another example, the end cap may include a removable panel that is coupled to at least one electronic circuit board and configured to secure at least one electronic circuit board when it is inside the end cap, and the removable panel may also be configured to be removed from the end cap when it is not inside the end cap.

[0044] Optionally, the energy storage assembly may also include a tag which may be coupled within an end cap and may be configured to move from an unlocked position to a locked position. In the locked position, the tag may cover an electrical port that accepts an electrical connector. In one embodiment, the tag may include a base fixed to the electrical port, a first hinge section coupled to the base, a second hinge section coupled to the first hinge section, and fasteners configured to fix the tag in the locked and unlocked positions. In another embodiment, the base may include an opening configured to lock in the locked position and fix the tag in the locked position. In one example, the battery operates in the range of 200 to 400 volts.

[0045] In one or more embodiments, an assembly is provided which may include a battery and an end cap mechanically and electrically coupled to the battery. The end cap may include a first section including an electrical connector having at least one electrical cable configured to supply current to at least one operating system electrically coupled to the battery. The end cap may also include a second section including at least one electronic circuit board coupled to the battery. The assembly may additionally include a service disconnector electrically coupled to the circuit including the battery and the electrical connector. The service disconnector may be configured to provide an electrical connection between the battery and the electrical connector in the connected position and to disconnect the battery and the electrical connector in the disconnected position. The assembly may also include a cover which may be coupled to the first section of the end cap to enclose the electrical connector within the first section. The cover may also include a tab portion positioned adjacent to the service disconnector such that the service disconnector engages with the tab portion when the service disconnector is in the connected position, thereby preventing the cover from moving.

[0046] Optionally, the cover may include an opening adjacent to at least one electrical cable to allow access to at least one electrical cable. In one embodiment, the end cap may include a magnet disposed therein. In another embodiment, the first section may include a cavity configured to mate and receive an electrical connector. The cavity may also be configured to adapt the clamp of a clamp sensor around at least one electrical cable. In one example, the cavity may include at least one channel configured to receive at least one electrical cable. In another example, the second section may include a removable panel coupled to an electronic circuit board and configured to provide access to at least one electronic circuit board without removing the end cap from the battery.

[0047] Optionally, the assembly may also include a tag coupled within a first section of the end cap and configured to move from an unlocked position to a locked position. In the locked position, the tag can cover an electrical port that accepts an electrical connector. In one embodiment, the tag may include a base fixed to the electrical port, a first hinge section coupled to the base, a second hinge section coupled to the first hinge section, and fasteners configured to fix the tag in the locked and unlocked positions. In one example, the base may include an opening configured to lock in the locked position and fix the tag in the locked position.

[0048] In one or more embodiments, an assembly is provided which may include a battery and an end cap mechanically and electrically coupled to the battery. The end cap may include a first section which includes an electrical connector having at least one electrical cable configured to supply current to at least one operating system electrically coupled to the battery. The end cap may also include a second section which includes at least one electronic circuit board coupled to the battery. The assembly may also include a tag coupled within the first section of the end cap which is configured to move from an unlocked position to a locked position. In the locked position, the tag may cover an electrical port that accepts the electrical connector.

[0049] Optionally, the tag may include a base fixed to an electrical port, a first hinge section coupled to the base, a second hinge section coupled to the first hinge section, and fasteners configured to secure the tag in a locked and unlocked position. In one embodiment, the base includes an opening configured to lock in the locked position and secure the tag in that position.

[0050] As used herein, the terms “processor” and “computer,” as well as related terms, such as “processing device,” “computing device,” and “controller,” may not be limited to integrated circuits referred to in the art as computers, but may also refer to microcontrollers, microcomputers, programmable logic controllers (PLCs), field-programmable gate arrays, and application-specific integrated circuits, as well as other programmable circuits. Suitable memory may include, for example, computer-readable media. Computer-readable media may be, for example, computer-readable non-volatile media such as random-access memory (RAM) and flash memory. The term “non-temporary computer-readable media” refers to tangible computer-based devices implemented for short-term and long-term storage of information such as computer-readable instructions, data structures, program modules and submodules, or other data in any device. Thus, the methods described herein may be encoded as executable instructions embodied in tangible non-temporary computer-readable media, including but not limited to storage devices and / or memory devices. When such instructions are executed by a processor, they cause the processor to execute at least a portion of the methods described herein. Therefore, this term includes tangible computer-readable media, including but not limited to volatile and non-volatile media, and non-temporary computer storage devices, as well as removable and non-removable media such as firmware, physical and virtual memory, CD-ROMs, DVDs, and other digital sources such as networks or the internet.

[0051] The singular forms “a,” “an,” and “the” include plural references unless the context explicitly indicates otherwise. “Optional” or “optionally” means that the event or situation described thereafter may or may not occur, and the description may include both the event occurring and the event not occurring. The approximation language used herein throughout this specification and the claims may be applied to modify any quantitative expression that can be acceptablely changed without altering the fundamental function to which it may relate. Thus, values ​​modified by terms or plural terms such as “about,” “substantially,” and “approximately” may not be limited to the specified exact value. In at least some cases, the approximation language may correspond to the precision of an instrument for measuring a value. Throughout this specification and the claims, unless the context or language otherwise indicates, range limitations may be combined and / or interchangeable, and such ranges may be specified and may include all subranges contained therein.

[0052] This written description, using examples, discloses embodiments including best modes and enables a person skilled in the art to practice embodiments including the manufacture and use of any device or system and the execution of any incorporated methods. The claims define the patentable scope of this disclosure and include other examples that may arise for a person skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements that are substantially different from the literal language of the claims.

Claims

1. 1. An assembly comprising: an end cap configured to be mechanically and electrically coupled to an energy storage device, the end cap including an electrical connector having at least one electrical cable configured to supply electrical current to at least one vehicle operating system electrically coupled to the energy storage device; the end cap also includes at least one electronic board configured to be coupled to the energy storage device; an assembly configured to be removed from the energy storage device to provide access to the electrical connector and the at least one electronic board;

2. 10. The assembly of claim 1, further comprising: a service disconnector configured to be electrically coupled to a circuit including or connected to the energy storage device and the electrical connector, the service disconnector configured to provide an electrical connection between the energy storage device and the electrical connector in a connected position and to disconnect the energy storage device and the electrical connector in a disconnected position.

3. The assembly of claim 2 , wherein the service disconnector is configured to be secured within the end cap in the connected position, and the service disconnector is configured to be removed from the end cap in the disconnected position.

4. The assembly of claim 2 , further comprising a cover coupled to the end cap and configured to house the electrical connector within the end cap.

5. The assembly of claim 4 , wherein the cover is coupled to the service disconnector to prevent removal of the cover when the service disconnector is in the connected position.

6. The assembly of claim 4 , wherein one or more of the cover or the end cap includes a magnet configured to provide a magnetic field detectable by a gaussmeter.

7. The assembly of claim 1 , wherein the end cap includes a cavity configured to receive the electrical connector, the cavity configured to accommodate a clamp of a clamp sensor around the at least one electrical cable.

8. The assembly of claim 1 , wherein the at least one electronic board is at least one of a wireless transmission card or a computer processing unit card.

9. 2. The assembly of claim 1, wherein the end cap includes a first section including the electrical connector and a second section including the at least one electronic board, the second section configured to provide access to the at least one electronic board without removing the end cap from the battery.

10. 10. The assembly of claim 1, wherein the end cap includes a removable panel coupled to the at least one electronic board and configured to secure the at least one electronic board when in the end cap and configured to be removed from the end cap when not in the end cap.

11. 10. The assembly of claim 1, further comprising a tag coupled within the end cap and configured to move from an unlocked position to a locked position, the tag covering an electrical port that receives the electrical connector in the locked position.

12. 12. The assembly of claim 11, wherein the tag includes a base secured to the electrical port, a first hinge section coupled to the base, a second hinge section coupled to the first hinge section, and a fastener configured to secure the tag in the locked and unlocked positions.

13. 1. An assembly comprising: an energy storage device; an end cap including a first section including an electrical connector mechanically and electrically coupled to a battery and having at least one electrical cable configured to supply current to at least one operating system electrically coupled to the battery; an end cap also including a second section including at least one electronic board coupled to the battery; a service disconnector electrically coupled in a circuit including the battery and the electrical connector, the service disconnector configured to provide an electrical connection between the battery and the electrical connector in a connected position and to disconnect the battery and the electrical connector in a disconnected position; a cover coupled to the first section of the end cap to enclose the electrical connector within the first section, the cover including a tab portion positioned adjacent to the service disconnector such that the service disconnector engages the tab portion to prevent movement of the cover when the service disconnector is in the connected position.

14. The assembly of claim 13 , wherein the cover includes an opening adjacent the at least one electrical cable to allow access to the at least one electrical cable.

15. 14. The assembly of claim 13, wherein the first section includes a cavity configured to matingly receive the electrical connector, the cavity also configured to accommodate a clamp of a clamp sensor around the at least one electrical cable.

16. 14. The assembly of claim 13, wherein the second section includes a removable panel coupled to the electronic board and configured to provide access to the at least one electronic board without removing the end cap from the battery.

17. 14. The assembly of claim 13, further comprising a tag coupled within the first section of the end cap and configured to move from an unlocked position to a locked position, the tag covering an electrical port that receives the electrical connector in the locked position.

18. 1. An assembly comprising: an end cap including a first section including an electrical connector mechanically and electrically coupled to a battery and having at least one electrical cable configured to supply current to at least one operating system electrically coupled to the battery; an end cap also including a second section including at least one electronic board coupled to the battery; a tag coupled within the first section of the end cap and configured to move from an unlocked position to a locked position, wherein in the locked position, the tag covers an electrical port that receives the electrical connector.

19. 20. The assembly of claim 18, wherein the tag includes a base secured to the electrical port, a first hinge section coupled to the base, a second hinge section coupled to the first hinge section, and a fastener configured to secure the tag in the locked and unlocked positions.

20. 20. The assembly of claim 19, wherein the base includes an opening configured to receive a lock in the locked position to secure the tag in the locked position.

Images