Interface for connecting electric batteries to vehicle systems

Abstract

An apparatus for electrically and mechanically coupling a battery module to an electric vehicle includes an interface plate and one or more battery trays. The interface plate includes an electrical output that electrically couples the interface plate to the vehicle. The interface plate also includes an electrical input that is electrically coupled to the electrical output. The battery tray is configured to receive a plurality of replaceable battery modules and is removably mechanically coupled to the interface plate.

Description

[Technical field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims priority to U.S. patent application Ser. No. 17 / 221,510, entitled “INTERFACE FOR CONNECTING ELECTRIC BATTERIES AND VEHICLE SYSTEMS,” filed April 2, 2021, and incorporated herein by reference.

[0002] This application relates generally to electric vehicle systems and their battery components. [Background technology]

[0003] Various types of automobiles, such as electric vehicles (EVs), long-range electric vehicles, and hybrid electric vehicles, are equipped with energy storage systems that require periodic charging. Typically, this energy storage system can be charged by connecting to a power source, such as an AC supply line. Although it may be advantageous to recharge the vehicle's energy storage system before or after using the vehicle, current systems require the vehicle driver to manually plug the power line into the vehicle. Such manual operation is not always convenient for the vehicle driver and may result in missed charging opportunities or subsequent degradation of the vehicle's performance.

[0004] Automobiles have become a cultural staple and an essential part of the modern economy. Unfortunately, fossil fuels (usually used to power such vehicles) have many drawbacks, including that foreign sources are often in geographically unstable locations, and most problematic, fossil fuels cause pollution and climate change.

[0005] One way to address these issues is to improve the fuel efficiency of these vehicles. In recent years, gasoline-electric hybrid vehicles have been introduced, which consume significantly less fuel than their traditional internal combustion counterparts, meaning they have better fuel economy. However, gasoline-electric hybrid vehicles still require an internal combustion engine in addition to the electric motor, and therefore do not eliminate the need for fossil fuels.

[0006] Another way to address this issue is to use renewable resource fuels such as biofuels. Although biofuels have been successful in other countries such as Brazil, they are still more expensive than outdated biofuels. But more importantly, biofuels contribute to greenhouse gases as well, and will likely leave a larger carbon footprint when analyzed from the overall production volume.

[0007] A more common approach is to use cleaner technologies such as fuel cells and electric motors powered by batteries. However, many of these clean technologies are not yet commercially available. For example, fuel cell cars are still in development and expensive. Hydrogen-powered fuel cells start by burning diatomic hydrogen (H 2 ) and transport by vehicle, which is inherently dangerous.

[0008] The biggest obstacle for EVs, especially long-range EVs, has been and continues to be outdated battery technology. Battery technology has made some progress recently. However, batteries still make up 40% of the cost of a new car. Rechargeable battery technology has not advanced enough to provide mass-produced, cost-effective batteries to power EVs over long distances.

[0009] Current electrochemical (rechargeable battery) technology does not allow for comparable energy density when compared to chemically stored energy sources. Gasoline, diesel, ethanol, methanol, etc. have roughly two orders of magnitude higher energy density than lithium-ion rechargeable batteries. Thus, a typical fully charged electric vehicle battery may only get around 70 miles (EPA Nissan Leaf) before needing to be recharged. If you are not a hybrid, range becomes a severe limiting factor, and you may imagine being stranded with no charging capability nearby.

[0010] Additionally, batteries can take many hours to recharge, and in some cases, must be recharged overnight. State and local governments have recognized the need for charging stations to mitigate the drawbacks (or more accurately, obstacles) to the use and widespread adoption of electric vehicles. An electric vehicle charging station is an element of infrastructure that provides electrical energy for the charging of electric vehicles, including fully electric vehicles, neighborhood electric vehicles, and plug-in electric vehicles such as plug-in hybrids.

[0011] As ownership of plug-in hybrid electric vehicles and electric vehicles expands, there is an increasing need for widely distributed and publicly accessible charging stations, some of which support fast charging at higher voltages and currents than are available from residential electric vehicle supply facilities (EVSE). Many charging stations are installed at utility-provided roadside facilities, or in retail shopping centers, and many are operated by private companies. These charging stations offer one or several heavy-duty or specialized connectors that comply with various charging connector standards.

[0012] Unfortunately, charging stations are not everywhere, and fast charging can take several hours, even though higher current capacity shortens recharging times. Therefore, current EV owners need to plan their trips carefully and thoughtfully. Moreover, in some cases, a lack of infrastructure or vehicle range simply makes long-distance travel impossible. Summary of the Invention [Problem to be solved by the invention]

[0013] What is needed is an easy-to-use system and method for replacing modular battery packs in any remote location without the need for long charging times in existing systems. [Means for solving the problem]

[0014] The exemplary embodiments described herein have innovative features, no single feature of which is essential or solely responsible for its desirable characteristics. The following description and drawings detail certain exemplary implementations of the present disclosure, illustrating some exemplary ways in which various principles of the present disclosure may be implemented. However, the illustrative examples do not exhaust the many possible embodiments of the present disclosure. Without limiting the scope of the claims, some of the advantageous features will now be summarized. Other objects, advantages, and novel features of the present disclosure will become apparent from the following detailed description of the present disclosure, taken in conjunction with the drawings, which are intended to illustrate, not limit, the present invention.

[0015] One aspect of the invention relates to an apparatus for electrically and mechanically coupling removable battery modules to a vehicle, the apparatus including an interface plate configured to be mechanically coupled to the vehicle, the interface plate having an interface plate electrical output electrically coupling the interface plate to the vehicle and an interface plate electrical input electrically coupled to the interface plate electrical output, the apparatus further including battery trays for releasably receiving the removable battery modules, each battery tray releasably mechanically coupled to the interface plate and having one or more battery module connectors releasably electrically coupled to a corresponding one or more battery modules and a battery tray electrical output electrically coupling the one or more battery module connectors to the interface plate electrical input.

[0016] In one or more embodiments, the interface plate and each battery tray include complementary threaded fasteners that releasably mechanically couple the battery tray and the interface plate. In one or more embodiments, the interface plate further includes first mechanical threaded fasteners, motors, each motor in mechanical communication with a corresponding first threaded fastener, and a controller in electrical communication with the motors. In one or more embodiments, each battery tray further includes second threaded fasteners, each second threaded fastener aligned with a corresponding first threaded fastener. The controller sends a first signal to each motor that mechanically engages the corresponding first threaded fastener with the second threaded fastener, and the controller sends a second signal to each motor that mechanically disengages the corresponding first threaded fastener from a respective second threaded fastener.

[0017] In one or more embodiments, the interface plate includes a microprocessor in electrical communication with each motor and controlling whether the corresponding first mechanical threaded fastener is engaged or disengaged with the respective second threaded fastener. In one or more embodiments, the interface plate further includes a gear system, each gear system mechanically translating rotation of a respective motor into rotation of a respective first mechanical connector. In one or more embodiments, The first mechanical connector comprises a nut and the second mechanical connector comprises a bolt.

[0018] In one or more embodiments, each battery tray includes an alignment peg that defines a position of one or more battery modules for receiving the corresponding one or more battery modules on the battery tray. In one or more embodiments, each alignment peg extends from a first end to a second end, the first end being disposed on the battery tray, and the second end tapering from a first thickness equal to a thickness of the first end to a second thickness less than the first thickness. In one or more embodiments, the thickness of the first end is configured to reduce lateral movement of the respective battery module.

[0019] In one or more embodiments, the battery tray electrical output electrically couples the output of one or more adjacent battery modules to the interface plate electrical input. In one or more embodiments, the interface plate electrical input is electrically coupled to a conductive bus bar or conductive wire that extends to the interface plate electrical output. In one or more embodiments, the interface plate includes a flange including a position indication marking, the position indication marking including a light emitting diode (LED), a light reflective material, or a machine detectable marking. In one or more embodiments, the interface plate includes a microprocessor in electrical communication with the position indication marking to control the light emitting diode, light reflective material, or machine detectable marking.

[0020] Another aspect of the invention relates to an interface plate configured to be mechanically coupled to a vehicle having an electrical output electrically and mechanically coupling the interface plate to the vehicle, an electrical input including a first electrical connector configured to mate with a complementary electrical connector in a removable battery tray constructed and arranged to hold a plurality of replaceable battery modules, and a conductive bus bar or conductive wire electrically coupling the electrical input to the electrical output.

[0021] In one or more embodiments, the interface connector further comprises a flange and a position indicator disposed on the flange and comprising a controllable light emitting diode, In one or more embodiments, the interface connector further comprises a microprocessor in electrical communication with the position indicator for controlling the light emitting diode. [Brief description of the drawings]

[0022] For a more complete understanding of the nature and advantages of the present concepts, reference is now made to the following detailed description of the preferred embodiments taken in conjunction with the accompanying drawings. [Figure 1] FIG. 1 is an isometric view of a robot-assisted modular battery exchange system according to one or more embodiments. [Diagram 2] FIG. 2 illustrates an example of a semi-autonomous lift system for lifting a vehicle, according to one or more embodiments. [Diagram 3] FIG. 3 is a bottom perspective view of the semi-autonomous lift system shown in FIG. 2 engaging and lifting respective wheels of a vehicle, according to one or more embodiments. [Figure 4] FIG. 4 shows a bottom view of a vehicle being raised by a set of lift systems to access the battery storage compartment, according to one or more embodiments. [Diagram 5] FIG. 5 is an exploded perspective view of a battery storage compartment according to one or more embodiments. [Figure 6] FIG. 6 is a perspective view of an exemplary battery tray with removable battery modules according to one or more embodiments. [Figure 7] FIG. 7 is a perspective view of an exemplary battery tray with the battery modules removed, according to one or more embodiments. [Figure 8A-8C] 8A, 8B, and 8C show detailed views of the length alignment peg, the first corner alignment peg, and the second corner alignment peg, respectively, shown in FIG. 7, according to one or more embodiments. [Figure 9] FIG. 9 is an exploded perspective view of a portion of an exemplary battery tray with a battery module removed, according to one or more embodiments. [Figure 10] FIG. 10 is a detailed view of a tray electrical connector according to one or more embodiments. [Figure 11] FIG. 11 is an exploded perspective view of the tray electrical connector shown in FIG. 10 according to one or more embodiments. [Figure 12] FIG. 12 shows a perspective view of an interface connector and a tray electrical connector according to one or more embodiments. [Figure 13] FIG. 13 is a detailed view of a threaded attachment mechanism according to one or more embodiments. [Figure 14] FIG. 14 is a cross-sectional view of the threaded attachment mechanism shown in FIG. 13 according to one or more embodiments. [Figure 15] FIG. 15 is a perspective view of the bottom of the interface plate shown in FIG. 5 according to one or more embodiments. [Figure 16] FIG. 16 is a perspective view of an exemplary threaded attachment mechanism according to one or more embodiments. [Figure 17] FIG. 17 is a cross-sectional view of a threaded mounting assembly including one or more threaded mounting features, according to one or more embodiments. [Figure 18] FIG. 18 is a perspective view of the top surface of an interface plate according to one or more embodiments. [Figure 19] FIG. 19 is a perspective view of the top of an interface plate without an interface cover in accordance with one or more embodiments. [Figure 20] FIG. 20 is a perspective view of the top of the interface plate without the interface cover, the cover for the controller box, and the bus bar cover in accordance with one or more embodiments. [Figure 21] FIG. 21 is a perspective view of a conductive bus bar according to one or more embodiments. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] 1 is an isometric view of a robot-assisted modular battery exchange system 100 in accordance with one or more embodiments. The robot-assisted modular battery exchange system 100 includes a battery exchange robot 120 and a mobile manipulation platform 130.

[0024] In the most general sense, mobile operating platform 130 is a device responsible for storing batteries, distributing them when needed, and storing returned empty batteries. In one or more embodiments, mobile operating platform 130 charges (or maintains, per a battery tender) discharged batteries on-site, or in other embodiments, simply serves as a shipping container for batteries to be charged elsewhere.

[0025] The battery exchange robot 120 is either autonomous or automated, receiving a more explicit set of instruction codes from the mobile operation platform 130. In practice, the battery exchange robot 120 utilizes relative position sensing technology 140 (such as ultrasonic multilateration, ultrasonic radar, infrared multilateration, LiDAR, or any similar technology) to determine its position relative to the vehicle 110. Using its position relative to fixed points on the vehicle 110 and instructions wirelessly communicated from the mobile operation platform 130, the battery exchange robot 120 positions itself underneath the vehicle 110 to remove one or more discharged batteries (e.g., a tray containing one or more discharged batteries) or install one or more charged batteries (e.g., a tray containing one or more charged batteries). Before the battery exchange robot 120 removes or installs a battery, the vehicle 110 is lifted to provide sufficient vertical space for the removal and / or installation of the battery.

[0026] FIG. 2 shows an example of a semi-autonomous lift system 20 for lifting a vehicle, according to one or more embodiments. Each lift system 20 engages with a wheel 222 of the vehicle 110. Each wheel 222 can be considered a load for the respective lift system 20. In this example, the wheels 222 can also include tires, and for the present purposes, the method or system of the present invention does not change, and the load-bearing arms 120 of the lift system 20 can also engage with tires (for simplicity, we will simply refer to them as wheels for some or all of this example). In one embodiment, two parallel load-bearing arms 220 of the lift system 20 support the tires / wheels 222 of the vehicle 120, and thus the load is placed between the two load-bearing arms 220 for lifting from the ground 211.

[0027] 3 is a bottom perspective view of the lift system 20 engaging and lifting each wheel 222 of the vehicle 110, according to one or more embodiments. Raising the wheels 222 raises the body of the vehicle 110 (e.g., after compressing the springs of the suspension system) and increases the clearance between the underside 112 of the vehicle 110 and the ground (e.g., ground surface 211), thereby allowing the robot 120 to access the battery storage compartment 300 of the vehicle 110.

[0028] The battery storage compartment 300 includes a bottom cover plate 310 that can be secured in place by a number of bolts or fasteners 320 and can be removed (e.g., by a machine or service robot) to access the equipment or batteries within the cover. Additionally, one or more fiducial or locator marks 330 on the bottom of the battery storage compartment 300 can be used to generally indicate its location relative to the underside 112 of the vehicle 110.

[0029] FIG. 4 illustrates a bottom view of the vehicle 110 lifted by a set of lift systems 20 to access the battery storage compartment 300, according to one or more embodiments. In a particular example, one or more chassis reference position markers 330 on the bottom of the battery storage compartment 300 include a series of equally spaced LED light sources 330a arranged on a pair of orthogonal line segments, such as in the shape of a cross (although other configurations are possible as well). The locating or fiducial marks 330 can be used to identify, locate, or guide other equipment to a predetermined location (e.g., through image processing and geometric / trigonometric calculations) for servicing the underside of the vehicle 110. An undercarriage camera 432 can use light lines of sight 432a to one or more locating or fiducial marks 330 to identify, locate, or guide other equipment to a predetermined location for servicing the underside 112 of the vehicle 110. The locating or fiducial marks 330 can be used to guide a service robot 401 using wireless control signals 410. Communication with the service robot 201 can be direct between the robot 401 and the lift system 20 in some embodiments, or can be via a remote control unit that sends control signals 410 to the service robot 401. In some embodiments, the service robot 401 is the same as the battery exchange robot 120 and / or the remote control unit 400 is the same as the mobile manipulation platform 130.

[0030] 5 is an exploded perspective view of a battery storage compartment 500 according to one or more embodiments. In some embodiments, the battery storage compartment 500 is an example of the battery storage compartment 300.

[0031] The battery storage compartment 500 includes an interface plate 501 and removable battery trays 502. Each battery tray 502 includes a removable battery module 503, and each battery module 503 can include one or more batteries (e.g., rechargeable batteries) for powering the electric vehicle. It is noted that while four battery trays 502 are shown in FIG. 5, the interface plate 501 can be configured to accept fewer or additional battery trays 502. Additionally or alternatively, while FIG. 5 shows each battery tray 502 includes four batteries, in other embodiments, the battery trays 502 can include fewer or additional batteries. It is also noted that the interface plate 501 can accept at least a first battery tray 502 including a first battery module 503A (not shown) and at least one second battery tray 502 including a second battery module 503B (not shown). The first battery module 503A can include batteries having a first specification or first characteristic, and the second battery module 503B can include batteries having a second specification or second characteristic, where the first specification / characteristic is different or the same as the second specification / characteristic.

[0032] When the battery modules 503 in a given battery tray 502 become discharged or depleted, the battery tray 502 can be replaced with a replacement battery tray 602 containing charged battery modules 503. This eliminates the need to wait several hours for the vehicle's battery to fully charge at a charging station or at home. The battery modules 503 can then be charged while still in the tray 502 or removed from the tray 502 and charged using another device.

[0033] FIG. 6 is a perspective view of an exemplary battery tray 502 with battery modules 503 according to one or more embodiments. The battery tray 502 is configured to receive four battery modules 503 disposed on a flat tray surface of the battery tray 502. An outer tray wall 600 extends around the periphery of the battery tray 502. Threaded attachment mechanisms 610 are disposed at corners of the outer tray wall. The threaded attachment mechanisms 610 are configured to mate with complementary threaded attachment mechanisms disposed on the interface plate 501. For example, the threaded attachment mechanisms 610 can comprise bolts and the threaded attachment mechanisms disposed on the interface plate 501 can comprise nuts (or vice versa). Additionally, the battery tray 502 includes first and second tray electrical connectors 620A, 620B (generally, tray electrical connectors 620) that electrically couple the battery modules 503 to corresponding electrical connectors on the interface plate 501.

[0034] 7 is a perspective view of an exemplary battery tray 502 with a battery module 503 removed, according to one or more embodiments. The battery tray 502 includes an interior wall 630 in the center of the battery tray 502 that extends across the center of the opposing tray exterior wall 600 to define first and second battery tray sections 701, 702. Each battery tray section 701, 702 is configured to receive two battery modules 503. For example, the battery tray section 701 is configured to receive first and second battery modules 503A, 503B (not shown) at first and second battery module positions 705, 706, respectively (typically one or more such connectors depending on expected redundancy needs and / or power level requirements). Similarly, the battery tray section 702 is configured to receive third and fourth battery modules 503C, 503D (not shown) at third and fourth battery module positions 703, 704, respectively. Visual identification markings 710 are placed on the planar tray surface 720 to identify the battery module positions 703-706 for the robot to place each battery module 503 therein.

[0035] The alignment pegs 730 further define positions for positioning each battery module 503 in orthogonal first and second directions (e.g., along the "x" and "y" axes of the battery tray 502) within a tolerance range (e.g., about 1 mm to about 2 mm). The alignment pegs 730 include a length alignment peg 731, a first corner alignment peg 732, a second corner alignment peg 733, and a width alignment peg 734. Each alignment peg 731-734 has a tapered upper portion 740.

[0036] Figure 7 shows a tray which holds the battery. Figure 6 shows the tray with the battery inserted. Figures 6 and 7 are top views of a tray typically used in road vehicles. The tray is inserted into a plate (Figure 5 is a view from underneath the plate) and locked into place. The tray in Figure 7 may include a metal object to protect the battery therein.

[0037] 8A-C show detailed views of the length alignment peg 731, the first corner alignment peg 732, and the second corner alignment peg 733, respectively, according to one or more embodiments. The cross-sectional thickness is smaller at the top 741 of the tapered top 740 than at the bottom 742. In some embodiments, the cross-sectional thickness can be about 1 mm, about 1.5 mm, or about 2 mm (or any cross-sectional thickness, or a range of cross-sectional thickness between any two of the aforementioned values), or can increase from the top 741 to the bottom 742 of the tapered top 740. In certain embodiments, the top 741 of the tapered top 740 can have a cross-sectional thickness of about 3 mm, about 3.5 mm, or about 4 mm (or any cross-sectional thickness, or a range of cross-sectional thickness between any two of the aforementioned values), and the bottom 742 of the tapered top 740 can have a cross-sectional thickness of about 5 mm, about 5.5 mm, or about 6 mm (or any cross-sectional thickness, or a range of cross-sectional thickness between any two of the aforementioned values).

[0038] The tapered tops 740 of each alignment peg 731-734 can help align the battery module 503 to the appropriate position (e.g., one of the battery module positions 703-706) on the tray surface 720 when the battery module 503 is placed by the robot. For example, in some embodiments, the robot can place the battery module 503 at a target position on the tray surface 720 within about 1 mm to about 2 mm in orthogonal first and second directions (e.g., the "x" and "y" directions of the tray surface 720). The tapered tops 740 of the alignment pegs 731-734 can correct for any misalignment due to robot placement errors.

[0039] The increased cross-sectional thickness of the lower portion 745 of each alignment peg 731-734 is designed to limit movement of each battery module 503 in orthogonal first and second directions when the battery module 503 is placed on the flat tray surface 720. Restraining movement can reduce vibration and potential damage to the battery module 503 while the vehicle 110 is in motion. In certain embodiments, the distance between each battery module 503 and its respective alignment peg 731-734 is about 0.2 mm, about 0.25 mm, about 0.3 mm, about 0.35 mm, or about 0.4 mm when the battery module 503 is centered. Thus, each battery module 503 can move up to twice this distance in the orthogonal first and second directions when moving between contacting alignment pegs 731-734 on opposite sides of the battery module 503.

[0040] 9 is an enlarged perspective view of a portion of an exemplary battery tray 502 with a battery module 503 removed, according to one or more embodiments. The view illustrates the location of each of the alignment pegs 731-734 of the battery modules. A first length alignment peg 731A is positioned proximate (e.g., adjacent, contacting, and / or facing) a first side 931 of the inner wall 630 of the battery tray 502. An identical second length alignment peg 731B (not shown) is positioned proximate (e.g., adjacent, contacting, and / or facing) a second side 932 of the inner wall 630 of the battery tray 502, in alignment with the first length alignment peg 731. Each alignment peg 731 is aligned with the center of a respective visual identification marking 710.

[0041] The first corner alignment peg 732 is positioned near the exterior wall 750 between the first and second battery module positions 703, 704. A first planar angle 932A of the first corner alignment peg 732 is positioned to face a corner of the first battery module when placed in the first battery module position 703. A second planar angle 932B of the first corner alignment peg 732 is positioned to face a corner of the second battery module 503B when placed in the second battery module position 704. The first and second planar angles 932A, 932B can align the first and second battery modules 503A,B in the "x" and "y" directions of the tray surface 720 (generally one or more such modules and their respective connectors).

[0042] The second corner alignment peg 733 is disposed at a corner of the first battery module position 703, near the exterior wall 750. A planar angle 933 of the second corner alignment peg 733 is disposed to face a corner of the first battery module 503A when disposed at the first battery module position 703. The planar angle 933 can align the first battery module 503A in the "x" and "y" directions of the tray surface 720. Thus, the first and second corner alignment pegs 732, 733 are configured and arranged to align two corners of the first battery module 503A in the "x" and "y" directions and constrain the first battery module 503A with respect to the "x" and "y" directions.

[0043] The width alignment peg 734 is located on the outer tray wall 600 and is centered along the length of the first battery module 503A when placed in the first battery module position 703. The width alignment peg 734 is located along the "X" direction of the tray surface 720 and can constrain the first battery module 503A in the "x" direction.

[0044] 9 also shows battery module connectors 910 having inputs configured to be releasably electrically coupled to the battery module 503 when the battery module 503 is in the first battery module position 703. The first and second battery module positions 703, 704 have output connectors that are electrically coupled to the first tray electrical connector 620A. Similarly, the battery module connectors 910 of the third and fourth battery module positions 705, 706 have outputs that are electrically coupled to the second tray electrical connector 620B.

[0045] While the above description has focused on the alignment pegs 731-734 and battery module connector 910 of the first battery module position 703, it should be noted that identical alignment pegs 731-734 and battery module connectors 910 are provided in the battery tray 502 for each battery module position 703-706.

[0046] When the battery tray 502 is not attached to the interface plate 501, the battery modules 503 can be removed from the battery tray 502. For example, the battery modules 503 can be removed (e.g., by robot or manually) and placed in a charging device. Alternatively, the battery tray 502 can be electrically coupled to a power source to charge the battery modules 503. The battery modules 503 can also be removed from the battery tray 502 if they are damaged or if they are nearing the end of their life. life. In another embodiment, when the battery module 503 is depleted, the battery module 503 can be removed and replaced with a charged battery module. Each battery module 503 can be removed by vertically lifting it off the tray surface 720, which disconnects the battery module output connector from the battery module connector 910.

[0047] 10 is a detailed view of a tray electrical connector 620 according to one or more embodiments. The tray electrical connector 620 includes first and second female electrical connectors 1001, 1002 configured to mate with corresponding first and second male electrical connectors in the interface plate 501. The exposed end of each female electrical connector 1001, 1002 includes a tapered portion 1005, which tapers from a wider diameter to a narrower diameter (e.g., tapers from about 3 mm to about 2 mm) and can aid in aligning the male electrical connector with the respective female electrical connector 1001, 1002.

[0048] The tray electrical connector 620 includes a base 1020 that includes first and second springs 1025, as shown in Figure 11. The springs 1025 allow the middle portion 1021 and the top portion 1022 to move laterally (e.g., perpendicular to the height of the tray electrical connector in the x or y direction) up to about 4.5 mm, about 5 mm, about 5.5 mm, or any value or range between any two of the above.

[0049] The upper portion 1021 includes an orifice 1100 configured to mate with a corresponding mechanical protrusion 1210 that is mechanically coupled to first and second male electrical connectors 1201, 1202 of an interface connector 1200, as shown in FIG.

[0050] FIG. 13 is a detailed view of threaded attachment mechanisms 610 located at each corner of the outer tray wall 600. The threaded attachment mechanism 610 includes a tapered cylindrical top 1300 that tapers from a wider diameter at the top 1301 to a narrower diameter at the bottom 1302. The threaded bolt 1310 is located within a cylindrical cavity 1320 extending from the bottom 1302 of the tapered cylindrical top 1300. The threaded bolt 1310 is attached to a spring 1340 as shown in FIG. 14, which is a cross-sectional view of the threaded attachment mechanism 610 through plane 14-14 of FIG. 13. The threaded bolt 1310 engages with a threaded nut located on a corresponding threaded attachment mechanism on the interface plate 501 (or vice versa). The tapered cylindrical top 1300 provides a self-aligning feature when the threaded nut is placed within the threaded attachment mechanism 610 to engage the threaded bolt 1310. Further details of the threaded attachment mechanism are disclosed in U.S. Patent Application Publication No. 2016 / 0369826, published Dec. 22, 2016, entitled "Automated Self-Aligning Mechanical Fastener," and incorporated herein by reference.

[0051] 15 is a perspective view of a bottom 1500 of an interface plate 501 according to one or more embodiments. The interface plate 501 includes four compartments 1510 for receiving four respective battery trays 502. Each compartment 1510 includes a threaded attachment mechanism 1520 at its corner that is configured to align and mate with a complementary threaded attachment mechanism 610 on the battery tray 502. For example, the threaded attachment mechanism 610 on the battery tray 502 can include a bolt and the threaded attachment mechanism 1520 on the interface plate 501 can include a nut (or vice versa). Additionally, each compartment 1510 includes two interface connectors 1200 including first and second male electrical connectors 1201, 1202.

[0052] The interface plate 501 also includes a flange 1505 disposed about the periphery of the four compartments 1510. Reference or position indication markings 1530 are disposed on the flange 1505 so as to be visible when the battery tray 502 is placed within the compartments 1510. The reference or position indication markings 1530 may be the same as the reference or position indication markings 330.

[0053] 16 is a perspective view of an exemplary threaded attachment mechanism 1620, which may be the same or different from each threaded attachment mechanism 1520. The threaded attachment mechanism 1620 includes a motor 1622 and a gear system 1624 that drives a nut 1626 to engage a corresponding bolt on the battery tray 502. Alternatively, the motor 1622 and gear system 1624 can drive a bolt that engages a corresponding nut on the battery tray 502.

[0054] FIG. 17 is a cross-sectional view of a threaded mounting assembly 1700 including threaded mounting features 610, 1620, according to one or more embodiments. The threaded mounting assembly 1700 may be the same or may include a threaded mounting feature 1620. For example, the cross-sectional view of the assembly 1700 may be through plane 17-17 of FIG. 16. The threaded mounting feature 1620 on the interface plate 501 engages with the threaded mounting feature 610 on the battery tray 502. Specifically, the motor 1622 drives a gear system 1624 to rotate a nut 1626 on the threaded bolt 1310 in the threaded mounting feature 1620 on the battery tray 602. Rotating the nut 1626 on the threaded bolt 1310 secures the threaded mounting features 610, 1620 together, which in turn secures the battery tray 502 to the interface plate 501 in combination with the other threaded mounting features 610, 1620.

[0055] 18 is a perspective view of a top surface 1800 of an interface plate 501, according to one or more embodiments. In operation, the top surface 1800 of the interface plate 501 is secured (e.g., by bolts, nuts, or other attachment mechanisms) to the underside of the vehicle 110. A cover 1510 extends across the top surface 1800 of the interface plate 501 to physically protect the underlying electrical structure. The interface cover 1510 is disposed over a gasket 1520 to provide a waterproof barrier to protect the underlying electrical structure. The gasket 1520 may include neoprene, rubber, silicone, polychlorotrifluoroethylene, or another material.

[0056] The emergency disconnect switch 1530 is disposed in a hole defined in the interface cover 1510. The emergency disconnect switch 1530 is configured to interrupt the flow of power from the battery module 503 to an interface output connector 1540 that is electrically coupled to the vehicle 110 when the interface plate 501 is secured to the underside of the vehicle 110.

[0057] 19 is a perspective view of the top surface 1800 of the interface plate 501 without the interface cover 1510, according to one or more embodiments. This view shows that electrical wires 1900 pass through holes 1910 in the interface plate 501 to electrically couple to the interface connector 1200 (e.g., first and second male electrical connectors 1201, 1202 on the interface connector 1200). Each set of electrical wires 1900 includes a first wire (e.g., carrying a positive current) that couples to the first male electrical connector 1201 and a second wire (e.g., carrying a negative current) that couples to the second male electrical connector 1202. Each electrical wire 1900 is electrically coupled to a conductive bus bar 2000 (FIGS. 20, 21) that is disposed under a bus bar cover 1920 and electrically coupled to the interface output connector 1540.

[0058] The top surface 1800 of the interface plate 501 also includes a controller box 1930 that houses controller circuitry including a microprocessor and memory containing instructions readable or executable by the microprocessor. Additionally, the top surface 1800 of the interface plate 501 includes mounting holes 1940 for securing the interface plate 501 to the underside of the vehicle 110.

[0059] 20 is a perspective view of the top 1800 of the interface plate 501 without the interface cover 1510, the cover for the controller box 1930, and the bus bar cover 1920, according to one or more embodiments. As shown, the controller box 1930 includes first, second, and third microprocessors 2010, 2020, 2025, and a memory module 2030. The memory module 2030 stores instructions (e.g., software) readable and / or executable by the first, second, and third microprocessors 2010, 2020, 2025.

[0060] The first microprocessor 2010 can be in electrical communication with a control system of the vehicle 110 via an interface plate signal output connector 2015 electrically coupled to the first microprocessor 2010. The first microprocessor 2010 can transmit to the control system of the vehicle 110 specifications of the battery module 503, the remaining energy of the battery module 503, and other data related to the battery storage compartment 500.

[0061] The second microprocessor 2020 is in electrical communication with the motors 1622 in each threaded attachment mechanism 1620 on the interface plate 501. The second microprocessor 2020 sends commands to each motor 1622 to engage or disengage a corresponding threaded attachment mechanism on the battery tray 502. The second microprocessor 2020 can be in direct or indirect electrical communication with an external robot (e.g., the lift robot 20, the battery exchange robot 120, and / or the mobile work platform 130) and / or the mobile operation platform 130, and / or an external control system to determine when to send the appropriate commands. In some embodiments, the second microprocessor 2020 is in electrical communication with the first microprocessor 2010 and in direct or indirect communication with an external robot (e.g., the lift robot 20, the battery exchange robot 120, and / or the mobile operation platform 130) and / or an external control system.

[0062] The third microprocessor 2025 is in electrical communication with the reference or position indication marks 1530 to control the lights (e.g., light emitting diodes) on the reference or position indication marks 1530. For example, the third microprocessor 2025 may control the light frequency of each reference or position indication mark 1530, the duration and / or frequency that each reference or position indication mark 1530 is on, and / or the sequence or pattern of turning the reference or position indication marks 1530 on / off.

[0063] FIG. 21 is a perspective view of a conductive bus bar 2000 according to one or more embodiments. The conductive bus bar 2000 includes first and second conductive bars 2101, 2102 that extend to first and second ends 2110, 2120 of the conductive bus bar 2000, respectively. At the first end 2110, the first and second conductive bars 2101, 2102 are physically and electrically coupled to the interface output connector 1540. The conductive bus bar 2000 can be formed of copper, aluminum, silver, or another conductive material. A service disconnect 1531 allows for disconnecting the voltage in the system during maintenance of the plate. In some embodiments, the conductive material (e.g., copper) is coated with nickel or another corrosion resistant material to prevent corrosion. A portion of the bus bar 2000 can be coated with an insulating material, such as epoxy powder or another insulating material. In some embodiments, all surfaces of the conductive busbar 2000 are coated with an insulating material, except for locations that make physical and electrical contact with the electrical wires 1900 and the terminals of the interface output connector 1540.

[0064] The first conductive bar 2101 may be electrically coupled (e.g., via the interface output connector 1540) to a fuse circuit 2130 that cuts off power to the vehicle 120 if the current passing through the first conductive bar 2101 exceeds a predetermined maximum current.

[0065] The present invention should not be considered limited to the particular embodiments described above, but should be understood to cover all aspects of the invention as clearly set forth in the appended claims. Various modifications, equivalent processes, and numerous structures to which the present invention may be applicable will be apparent to those of skill in the art to which the present invention is directed upon review of this disclosure. The claims are intended to cover such modifications and equivalents.

Claims

1. 1. An apparatus for electrically and mechanically coupling a removable battery module to a vehicle, comprising: an interface plate configured to be mechanically coupled to the vehicle, an interface plate electrical output electrically coupling the interface plate to the vehicle; an interface plate electrical input electrically coupled to the interface plate electrical output; an interface plate having a battery tray for releasably receiving the removable battery module, each battery tray being releasably mechanically coupled to the interface plate; one or more battery module connectors releasably electrically coupled to a corresponding one or more battery modules; a battery tray electrical output electrically coupling the one or more battery module connectors to the interface plate electrical input; a battery tray having An apparatus having the above configuration.

2. 2. The apparatus of claim 1, wherein the interface plate and each battery tray include complementary threaded fasteners that releasably mechanically couple the battery tray and interface plate.

3. 3. The apparatus of claim 2, The interface plate further comprises a first mechanical threaded fastener; motors, each motor in mechanical communication with a corresponding first threaded fastener; a controller in electrical communication with the motor; Each battery tray further includes a second threaded fastener, each second threaded fastener aligned with a corresponding first threaded fastener; the controller sends a first signal to each motor causing a corresponding first threaded fastener to mechanically engage the second threaded fastener, and the controller sends a second signal to each motor causing the corresponding first threaded fastener to mechanically disengage from its respective second threaded fastener.

4. 4. The apparatus of claim 3, the interface plate including a microprocessor in electrical communication with each motor that controls whether the corresponding first mechanical threaded fastener is engaged or disengaged with the respective second threaded fastener.

5. 4. The apparatus of claim 3, wherein the interface plate further comprises gear systems, each gear system mechanically translating rotation of a respective motor into rotation of a respective first mechanical connector.

6. 4. The apparatus of claim 3, wherein the first mechanical connector comprises a nut and the second mechanical connector comprises a bolt.

7. 2. The apparatus of claim 1, wherein each battery tray includes alignment pegs that define the position of one or more battery modules for receiving the corresponding one or more battery modules on the battery tray.

8. 8. The apparatus of claim 7, wherein each alignment peg extends from a first end to a second end, the first end being positioned on a battery tray, the second end tapering from a first thickness equal to a thickness of the first end to a second thickness less than the first thickness.

9. 9. The apparatus of claim 8, a thickness of the first end configured to reduce lateral movement of each battery module.

10. 2. The apparatus of claim 1, the battery tray electrical output electrically couples an output of one or more adjacent battery modules to an electrical input of the interface plate.

11. 2. The apparatus of claim 1, The apparatus, wherein the interface plate electrical input is electrically coupled to a conductive bus bar or conductive wire that extends to the interface plate electrical output.

12. 10. The apparatus of claim 1, wherein the interface plate includes a flange including a position indication marking, the position indication marking including a light emitting diode (LED), a light reflective material, or a machine detectable marking.

13. 13. The apparatus of claim 12, The interface plate includes a microprocessor in electrical communication with the position indication marks to control the light emitting diodes, light reflective materials, or machine detectable markings.

14. An interface plate configured to be mechanically coupled to a vehicle, comprising: an electrical output that electrically and mechanically couples the interface plate to the vehicle; an electrical input including a first electrical connector configured to mate with a complementary electrical connector in a removable battery tray constructed and arranged to hold a plurality of replaceable battery modules; a conductive bus bar or wire electrically coupling the electrical input to the electrical output; An interface plate having

15. 15. The interface plate of claim 14, A flange; a position indicator disposed on the flange and comprising a controllable light emitting diode; The interface plate further comprises:

16. 16. The interface plate of claim 15, further comprising a microprocessor in electrical communication with said position indication markings for controlling said light emitting diodes.

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