Removal system for battery assembly

Abstract

A mounting and detachment system for a battery assembly is disclosed. The system may be positioned to be mounted on an electric vehicle powered by a battery pack disposed within the battery assembly. The system includes a pair of four-bar linkages that can be used to raise and lower the battery assembly. Each four-bar linkage includes a pair of hooks with different vertical positions. The hooks are positioned to grip a horizontal mounting bar disposed on the battery assembly. The vertically offset hooks allow the battery to be raised and lowered without rocking. [Selection diagram]

Description

Technical Field

[0001] Cross - reference to Related Applications

[0001] This PCT application claims the priority of U.S. Utility Patent Application No. 15 / 908,799, filed on February 28, 2018, the entire disclosure of which is incorporated herein by reference.

Background Art

[0002]

[0002] The present invention broadly relates to mining vehicles.

[0003]

[0003] Various types of mining vehicles can be used to extract and transport materials in mining operations. One type of vehicle, namely a haul truck, can be used. Conventional haul trucks may be powered by a diesel engine.

[0004]

[0004] Diesel - powered haul trucks can have various carrying capacities. Some trucks have a carrying capacity of 35 metric tons or more.

[0005]

[0005] Electric vehicles can operate with one or more electric motors powered by a battery. The batteries of electric vehicles, such as cars and other types of vehicles, can be large and heavy. External infrastructure such as a crane, lift, or other system may be required to remove the battery.

Summary of the Invention

[0006]

[0006] Various embodiments of mining vehicles are disclosed. The embodiments provide battery - powered mining vehicles instead of diesel - powered ones.

[0007]

[0007] In one embodiment, a battery attachment / detachment system for a battery assembly with a battery pack includes an operable assembly, an actuator for moving the operable assembly, and an engagement component on the operable assembly. The engagement component includes a first hook and a second hook, which are configured to engage with the battery assembly. The first hook has a first vertical position on the engagement component, and the second hook has a second vertical position on the engagement component. The first vertical position is substantially different from the second vertical position.

[0008]

[0008] In another embodiment, the battery replacement system includes an operable assembly, an actuator for moving the operable assembly, and an engaging component on the operable assembly. The engaging component includes a first hook and a second hook positioned below the first hook. The system also includes a battery cage comprising an outer casing for holding a battery pack, and a first retaining element and a second retaining element positioned below the first retaining element. The first hook is configured to engage with the first retaining element of the battery cage, and the second hook is configured to engage with the second retaining element of the battery cage.

[0009]

[0009] In another embodiment, the electric vehicle includes a battery cage capable of holding a battery pack for supplying power to the electric vehicle, and an onboard battery loading / unloading system for raising and lowering the battery cage. The battery loading / unloading system further includes a four-bar linkage mechanism. The four-bar linkage mechanism includes hooks for engaging with the battery cage.

[0010]

[0010] Other systems, methods, features, and advantages of the present invention will become apparent to those skilled in the art by examining the following drawings and detailed description. All such additional systems, methods, features, and advantages are included in this description and this summary, are within the scope of the present invention, and are intended to be protected by the following claims.

[0011]

[0011] The present invention can be better understood by referring to the following drawings and description. The components in the drawings are not necessarily to scale, and the emphasis is on illustrating the principles of the present invention. Furthermore, with respect to the drawings, the same reference numerals indicate corresponding parts across different drawings. [Brief explanation of the drawing]

[0012] [Figure 1]

[0012] A schematic diagram of one embodiment of a mining vehicle is shown. [Figure 2]

[0013] A schematic side view of one embodiment of a mining vehicle is shown. [Figure 3]

[0014] A schematic diagram of various internal components of a mining vehicle according to one embodiment is shown. [Figure 4]

[0015] This is a schematic side view of one embodiment of a mining vehicle. [Figure 5]

[0016] This is a schematic rear view of one embodiment of a mining vehicle. [Figure 6]

[0017] This is a schematic top view of one embodiment of a mining vehicle in a rotating position. [Figure 7]

[0018] This is a schematic diagram of one embodiment of a mining vehicle, showing the approximate envelope volume of the vehicle. [Figure 8]

[0019] This is a schematic diagram of one embodiment of a mining vehicle that does not have a battery assembly. [Figure 9]

[0020] Figures 9 to 11 are schematic diagrams of several embodiments of mining vehicles with different transport capacities. [Figure 10] Figures 9 to 11 are schematic diagrams of several embodiments of mining vehicles with different transport capacities. [Figure 11] Figures 9 to 11 are schematic diagrams of several embodiments of mining vehicles with different transport capacities. [Figure 12]

[0021] Schematic diagram of the dimensional tables of several different embodiments of an excavation vehicle. [Figure 13]

[0022] Schematic diagram of one embodiment of a chart showing the empty weight and towing weight of several excavation vehicles. [Figure 14]

[0023] Schematic diagram of one embodiment of a chart showing the output of several excavation vehicles. [Figure 15]

[0024] Schematic diagram of one embodiment of a chart showing the output-to-weight ratio of several excavation vehicles. [Figure 16]

[0025] Schematic diagram of one embodiment of a vehicle approaching a location for replacing a battery pack. [Figure 17]

[0026] Schematic diagram of a vehicle moving towards a predetermined location according to one embodiment. [Figure 18]

[0027] Schematic diagram of a set of power cables disconnected from the battery pack of a vehicle according to one embodiment. [Figure 19]

[0028] Figures 19 - 20 are schematic diagrams of a battery assembly lowered to the ground according to one embodiment. [Figure 20] Figures 19 - 20 are schematic diagrams of a battery assembly lowered to the ground according to one embodiment; [Figure 21]

[0029] Schematic diagram of a vehicle moving away from a removed battery assembly according to one embodiment. [Figure 22]

[0030] Schematic diagram of a vehicle moving from a first position to a second position close to a charged battery assembly according to one embodiment. [Figure 23]

[0031] Schematic diagram of the step of aligning an attachment system with a battery assembly according to one embodiment. [Figure 24]

[0032] Figures 24-25 are schematic diagrams of a battery assembly that can be lifted and mounted on a vehicle, according to one embodiment. [Figure 25] Figures 24-25 are schematic diagrams of a battery assembly that can be lifted and mounted on a vehicle, according to one embodiment. [Figure 26]

[0033] This is a schematic diagram of one embodiment of a set of power cables that have been reattached to a battery pack within a battery assembly. [Figure 27]

[0034] Figure 27 is a schematic diagram of a vehicle backing away from an area where a battery replacement process has been performed, according to one embodiment. [Figure 28]

[0035] This is a schematic diagram of a process for replacing a battery in an electric vehicle, according to one embodiment. [Figure 29]

[0036] This is a schematic perspective view of one embodiment of a battery assembly. [Figure 30]

[0037] This is a schematic perspective exploded view of one embodiment of a battery assembly. [Figure 31]

[0038] This is a schematic rear view of one embodiment of a battery assembly. [Figure 32]

[0039] This is a schematic perspective view of the front end of a vehicle equipped with a detachable system according to one embodiment. [Figure 33]

[0040] This is a schematic perspective view of one embodiment of a link mechanism assembly. [Figure 34]

[0041] Figures 34-38 are schematic side views of the range of motion of a link mechanism assembly according to one embodiment. [Figure 35] Figures 34-38 are schematic side views of the range of motion of a link mechanism assembly according to one embodiment. [Figure 36] Figures 34-38 are schematic side views of the range of motion of a link mechanism assembly according to one embodiment. [Figure 37]Figures 34-38 are schematic side views of the range of motion of a link mechanism assembly according to one embodiment. [Figure 38] Figures 34-38 are schematic side views of the range of motion of a link mechanism assembly according to one embodiment. [Figure 39]

[0042] This is a schematic perspective view of the correspondence between the mounting system and the mounting bar of the battery assembly according to one embodiment. [Figure 40]

[0043] Figures 40-45 are schematic side views of a process for lifting a battery assembly using a link mechanism assembly according to one embodiment. [Figure 41] Figures 40-45 are schematic side views of a process for lifting a battery assembly using a link mechanism assembly according to one embodiment. [Figure 42] Figures 40-45 are schematic side views of a process for lifting a battery assembly using a link mechanism assembly according to one embodiment. [Figure 43] Figures 40-45 are schematic side views of a process for lifting a battery assembly using a link mechanism assembly according to one embodiment. [Figure 44] Figures 40-45 are schematic side views of a process for lifting a battery assembly using a link mechanism assembly according to one embodiment. [Figure 45] Figures 40-45 are schematic side views of a process for lifting a battery assembly using a link mechanism assembly according to one embodiment. [Figure 46]

[0044] Figures 46-48 are schematic diagrams of another embodiment of the system for moving the battery. [Figure 47] Figures 46-48 are schematic diagrams of another embodiment of the system for moving the battery. [Figure 48] Figures 46-48 are schematic diagrams of another embodiment of the system for moving the battery. [Figure 49]

[0045] This is a schematic diagram of different loading positions for the vehicle and battery assembly according to one embodiment. [Figure 50]

[0046] This is a schematic diagram of the front end of a vehicle equipped with an alignment and locking system for a battery assembly, according to one embodiment. [Figure 51]

[0047] Figures 51-52 are schematic diagrams of a receiving member having an alignment portion and a locking mechanism according to one embodiment. [Figure 52] Figures 51-52 are schematic diagrams of a receiving member having an alignment portion and a locking mechanism according to one embodiment. [Figure 53]

[0048] Figures 53-54 are schematic diagrams of a horizontal mounting bar for a battery assembly that is secured in the appropriate location on the vehicle chassis, according to one embodiment. [Figure 54] Figures 53-54 are schematic diagrams of a horizontal mounting bar for a battery assembly that is secured in the appropriate location on the vehicle chassis, according to one embodiment. [Figure 55]

[0049] Figures 55-56 are schematic diagrams of a vertical mounting bar for a battery assembly that is secured in place on a vehicle chassis, according to one embodiment. [Figure 56] Figures 55-56 are schematic diagrams of a vertical mounting bar for a battery assembly that is secured in place on a vehicle chassis, according to one embodiment. [Figure 57]

[0050] Figures 57-58 are schematic diagrams of a battery assembly that is automatically positioned vertically by a set of receiving members, according to one embodiment. [Figure 58] Figures 57-58 are schematic diagrams of a battery assembly that is automatically positioned vertically by a set of receiving members, according to one embodiment. [Figure 59]

[0051] Figures 59-60 are schematic diagrams of a battery assembly that is automatically positioned horizontally by a set of receiving members. [Figure 60]Figures 59-60 are schematic diagrams of a battery assembly that is automatically positioned horizontally by a set of support members. [Figure 61]

[0052] This is another embodiment of an alignment and locking system for a battery assembly, according to one embodiment. [Figure 62]

[0053] This is a schematic side view of a vehicle showing the physical connection between the battery assembly and the vehicle chassis according to one embodiment. [Modes for carrying out the invention]

[0013]

[0054] Overview of mining vehicles

[0055] The embodiment relates to a vehicle, a zero-emission electric vehicle powered solely by a battery instead of a conventional diesel engine. The vehicle can be used for mining operations. The embodiment includes various equipment that enables the power supply of a transport truck having a carrying capacity of at least 40 metric tons using only electricity.

[0014]

[0056] The vehicles described herein are heavy-duty industrial electric vehicles designed to operate in continuous working environments such as underground mines. An overview of the underground mining environment and a general description of electric vehicles and power systems for underground mines are provided in concurrent application No. 15 / 133,478, filed April 20, 2016, entitled “System and Method for Powering Mining Operations,” the entire contents of which are incorporated herein by reference. The electric mining vehicle is powered by at least one heavy-duty, high-power battery pack comprising a plurality of battery modules housed in a pack housing. Each module comprises a plurality of cells. The modules may include an array of motion sensors and electronic components for providing data from the sensors to a separate maintenance network. The sensors may include temperature sensors, timing devices, charge level detectors, and other monitoring devices that may be employed to provide an operations center with accurate, real-time data on the module’s performance and its performance history. Details of these types of battery packs and related data generation and monitoring can be found in concurrently pending application No. 14 / 494,138 entitled “Modular Backbone System,” filed September 23, 2014; application No. 14 / 529,853 entitled “System and Method for Battery Pack Charging and Remote Access,” filed October 31, 2014; and application No. 14 / 721,726 entitled “Modular Maintenance System,” filed May 26, 2015, the entire contents of which are incorporated herein by reference.

[0015]

[0057] For clarity, the following terms may be used in the detailed description and specification. The term “carrying capacity” or simply “capacity” is used to characterize the amount of material that can be held in the vehicle’s bed and transported. Carrying capacity is also called “tramming capacity.”

[0016]

[0058] Figure 1 shows a schematic perspective view of vehicle 100. Figure 2 shows a schematic side view of vehicle 100. Referring to Figures 1 and 2, vehicle 100 may comprise a frame 101 (or chassis), a set of wheels 110, and a bed 112. The bed 112 may be connected to the frame 101 and may be tilted between a lowered position (shown in Figure 1) and a raised position (shown in Figure 2).

[0017]

[0059] For reference, vehicle 100 is also characterized as having a front end 90, a rear end 92, a first side 94, and a second side 96 (see Figure 1).

[0018]

[0060] Vehicle 100 is also equipped with various standard vehicle amenities, such as a driver's cab 116 for accommodating one or more drivers.

[0019]

[0061] In some embodiments, the vehicle 100 may be divided into a first frame section 122 and a second frame section 124 (see Figure 2). The first frame section 122 may be the front section associated with the driver's cab 116. The second frame section 124 may be the rear section associated with the bed 112. In some embodiments, a mechanical linkage mechanism 125 connects the first frame section 122 and the second frame section 124, allowing the two sections to move relative to each other (e.g., swivel or pivot).

[0020]

[0062] Figure 3 is a schematic diagram of vehicle 100 showing some internal components. Vehicle 100 also includes a propulsion system comprising one or more electric motors powered by one or more batteries. In some embodiments, vehicle 100 may include at least two electric motors to power each pair of wheels. In some embodiments, vehicle 100 may include four electric motors, each independently powering one of the four wheels. In the embodiment of Figure 3, vehicle 100 includes a first electric motor 180, a second electric motor 182, a third electric motor 184, and a fourth electric motor 186, which are collectively referred to as motor set 188. For illustrative purposes, the approximate location of each motor within motor set 188 is shown only schematically. It should be understood that the exact location of each motor may vary from one embodiment to another.

[0021]

[0063] In one embodiment, the electric motor in the vehicle 100 operates with a combined continuous torque of approximately 2000 Newton meters. In another embodiment, the electric motor in the vehicle 100 may operate with a combined continuous torque in the range of approximately 1500 to 2500 Newton meters.

[0022]

[0064] In one embodiment, the electric motor in the vehicle 100 operates with a combined continuous power of 440 kilowatts (590 horsepower) and a combined peak power of 560 kilowatts (750 horsepower). In another embodiment, the electric motor in the vehicle 100 may operate with a combined continuous power in the range of approximately 400 to 500 kilowatts. In yet another embodiment, the electric motor in the vehicle 100 may operate with a combined peak power in the range of approximately 500 to 600 kilowatts.

[0023]

[0065] Some embodiments may also be equipped with an auxiliary motor (not shown). In some cases, the auxiliary motor may operate with a continuous torque of about 700 Newton-meters. In some cases, the auxiliary motor may operate with a combined power of 125 kilowatts (167 horsepower). In some embodiments, the auxiliary motor can be used to drive other subsystems of the vehicle 100, such as a mechanical system that can be used for attaching and detaching the battery. Optionally, in other embodiments, the auxiliary motor may not be used.

[0024]

[0066] Embodiments may incorporate one or more batteries to supply power to the motor assembly 188 and / or auxiliary motors. As used herein, the term “battery pack” generally refers to a set of battery modules within a heavy-duty pack housing. Each module consists of a set of battery cells. Thus, a battery pack also refers to a collection of individual battery cells. The battery cells, and therefore the modules, are functionally interconnected as described in a previously incorporated pending application.

[0025]

[0067] In different embodiments, a battery pack can incorporate any suitable type of battery cell. Examples of battery cells include capacitors, ultracapacitors, and electrochemical cells. Examples of electrochemical cells include primary (e.g., disposable) and secondary (e.g., rechargeable) types. Examples of secondary electrochemical cells include lead acid, valve-regulated lead acid (VRLA), gels, absorbent glass mats (AGM), nickel-cadmium (NiCd), nickel-zinc (NiZn), nickel metal hydride (NiMH), lithium ions (Li-ions), and the like. Battery cells can have various voltage levels. In particular, in some cases, two different battery cells in a battery pack can have different voltage levels. Similarly, battery cells can have various energy capacity levels. In particular, in some cases, two different battery cells in a battery pack can have different capacity levels.

[0026]

[0068] In some cases, it may be desirable to use multiple battery packs. As used herein, the term “battery pack assembly,” or simply “battery assembly,” refers to a set of two or more battery packs. In some embodiments, the battery assembly may also include a cage or similar container for holding the separate battery packs together.

[0027]

[0069] As can be seen in Figures 1 to 3, the vehicle 100 is configured to include a primary battery assembly 104. In some embodiments, the primary battery assembly 104 may be located at the front end 90 and the second side 96 of the vehicle 100. In particular, the primary battery assembly 104 may be located adjacent to the driver's cab 116, which is located at the front end 90 and the first side 94 of the vehicle 100.

[0028]

[0070] Vehicle 100 may also include an auxiliary battery pack 105. The auxiliary battery pack 105 may be located separately from the primary battery assembly 104. As is most commonly seen in Figure 3, the auxiliary battery pack 105 may be located inside the vehicle 100. The interior of the vehicle 100 may be an area located inside the exterior of the vehicle (see Figure 7, described later). In some cases, the auxiliary battery pack 105 may be located in a compartment of a frame 101 designed to hold the auxiliary battery pack 105. As will be described later, the auxiliary battery pack 105 can be used to supply power to the vehicle 100 while the primary battery assembly is being replaced. The auxiliary battery pack 105 may also be referred to as a “traming battery”.

[0029]

[0071] As can be seen in Figures 1 and 2, the battery assembly 104 is exposed as part of the exterior of the vehicle 100. Specifically, various outer surfaces of the housing (i.e., the battery cage 210) that houses one or more battery packs can constitute part of the exterior of the vehicle 100. In contrast, the auxiliary battery pack 105 is an internal battery and is held within the chassis of the vehicle 100.

[0030]

[0072] The battery assembly 104 may be detachably mounted to the vehicle 100. As used herein, the term “detachably mounted” refers to two components that are joined together but can be separated without damaging one or the other component; that is, the components can be removed from each other non-destructively. Exemplary modalities of “detachable attachment” include connections made using detachable fasteners, latches, locking members, hooks, magnetic connections, and other types of connections.

[0031]

[0073] The auxiliary battery pack 105 may be "fixedly attached" to the vehicle 100. That is, the auxiliary battery pack 105 cannot be separated from the vehicle 100 without disassembling part of the vehicle 100 and / or destroying one or more components.

[0032]

[0074] In the embodiments shown in Figures 1 to 3, the primary battery assembly 104 comprises two battery packs. These include a first battery pack 200 and a second battery pack 202 (see Figure 3). The first battery pack 200 and the second battery pack 202 may be arranged in a stacked configuration with the first battery pack 200 positioned on top of the second battery pack 202. Furthermore, in some embodiments, the first battery pack 200 and the second battery pack 202 are held within a battery cage 210.

[0033]

[0075] In some embodiments, the primary battery assembly 104 can supply approximately 340 to 360 kilowatt-hours of work. In some cases, the first battery pack 200 and the second battery pack 202 can each supply approximately 170 to 180 kilowatt-hours of work. In some embodiments, the auxiliary battery pack 105 can supply approximately 40 to 50 kilowatt-hours of work.

[0034]

[0076] In some embodiments, each battery pack in the primary battery assembly 104 can power a different set of motors (and therefore a different set of wheels). In some cases, each battery pack can power a pair of motors on a specific axle (e.g., the front axle or the rear axle). In one embodiment shown in Figure 3, a first battery pack 200 may be connected to components on the front axle assembly 216 via a power cable 215. More specifically, the first battery pack 200 can power both the first electric motor 180 and the second electric motor 182 to power the front wheel set. Similarly, a second battery pack 202 may be connected to components on the rear axle assembly 217 via a power cable 217. More specifically, the second battery pack 202 can power both the third electric motor 184 and the fourth electric motor 186 to power the rear wheel set. By using separate battery packs to power the front and rear axles, the amount of power that must be supplied to a single source is reduced. This may allow for the use of smaller power cables (or cables with lower current ratings) that are easier to manage and / or less prone to failure.

[0035]

[0077] The embodiments may include a system for attaching and detaching one or more battery packs. In the embodiment shown in Figure 2, the vehicle 100 may incorporate an on-board attachment / detachment system 250. The attachment / detachment system 250 may include all the components necessary to lift and lower the primary battery assembly 104. Details of the attachment / detachment system 250 are discussed further below and are shown, for example, in Figures 32 to 45.

[0036]

[0078] Figures 4 to 15 and their accompanying descriptions disclose features related to the overall specifications of vehicle 100, including size, weight, capacity, and output.

[0037]

[0079] This embodiment can provide a zero-emission electric vehicle with a transport capacity equivalent to that of a diesel-powered vehicle of similar size.

[0038]

[0080] When discussing the shape factors of a vehicle, the description will refer to the vehicle's overall length, overall width, and overall height, as well as various other dimensions. The term "overall length" as used here refers to the distance between the foremost and rearmost points on the vehicle. In some cases, the foremost point may be located above the driver's cab or battery assembly. The term "overall width" refers to the distance between both sides of the vehicle, measured at the "outermost" points along both sides. The term "overall height" refers to the distance between the lowest point of the vehicle (usually the bottom of the wheels) and the highest point of the vehicle.

[0039]

[0081] Each of these vehicle dimensions may correspond to an axis or direction of vehicle 100. That is, the overall length of vehicle 100 may be taken along the length (or axis) of vehicle 100. The overall width of vehicle 100 may be taken along the width (or axis) of vehicle 100. The overall height of vehicle 100 may also be taken along the height (or axis) of vehicle 100.

[0040]

[0082] Figure 4 shows a schematic side view of the vehicle 100 (viewed from the first side 94) for the purpose of illustrating various dimensions. The vehicle 100 has a total height 300, which is measured vertically from the ground to the highest point of the vehicle 100. In one embodiment, the total height 300 has a value of approximately 2,206 millimeters. In other embodiments, the total height 300 can have any value in the range of approximately 1,500 to 2,500 mm. In the exemplary embodiment shown in Figure 4, it can be seen that the total height 300 can be measured from the wheels to the top of the bed 112 or to the top of the cab 116, since the tops of both components are in approximately the same horizontal plane.

[0041]

[0083] The vehicle 100 has an overall length 302 measured from the rearmost position of the frame 101 to the frontmost position of the frame 101. In one embodiment, the overall length 302 has a value of approximately 10,175 mm. In other embodiments, the overall length 302 can have any value within the range of approximately 9,000 to 12,000 mm.

[0042]

[0084] As can be seen in Figure 4, the overall length of the vehicle 100 can be broken down into a front overhang length 310, a wheelbase length 312, and a rear overhang length 314. Specifically, the wheelbase length 312 is measured between the centers of the front wheels 320 and the rear wheels 322. The front overhang length 310 is measured from the centers of the front wheels 320 to the foremost position of the vehicle 100 (i.e., the foremost position of the driver's cab 116). The rear overhang length 314 is measured from the centers of the rear wheels 322 to the rearmost position of the bed 112. In one embodiment, the front overhang length 310 has a value of approximately 3,429 mm, the wheelbase length 312 has a value of approximately 5,000 mm, and the rear overhang length 314 has a value of approximately 1,746 mm. Of course, in other embodiments, these values ​​can be modified to accommodate desired modifications to the wheelbase length, the length of the front and / or rear portions of the frame, or the size and / or extension of the bed. Furthermore, it should be understood that in different embodiments, the overall length is adjusted, so the values ​​of the front overhang length 310, the wheelbase length 312, and the rear overhang length 314 may be changed accordingly.

[0043]

[0085] Referring to Figures 2 and 4, the height of the bed 112 may vary depending on its operating position. For example, in the fully lowered position, the top of the bed 112 has a lowered bed height 330 measured from the ground. In one embodiment, the lowered bed height 330 is approximately equal to the total height 300 of the vehicle 100 (i.e., about 2,200 mm). In the fully raised position, the top of the bed 112 has a raised bed height 332 measured from the ground. In one embodiment, the raised bed height 332 is about 5,389 mm. Furthermore, in some cases, the raised bed height 332 corresponds to a position of the bed 112 where the bed 112 forms an angle 339 with the horizontal plane of the vehicle 100. In some cases, the angle 339 is about 70 degrees.

[0044]

[0086] As shown in Figures 2 and 4, the vehicle 100 may have a clearance height 335, defined as the vertical distance between the bottom of the wheels and the lower side of the frame 101. In some cases, the clearance height 335 may correspond to the height of the bottom of the bed 112, as seen in Figure 4. In one embodiment, the clearance height 335 has a value of approximately 323 mm (or 12.7 inches). In other embodiments, the clearance height 335 can be in the range between approximately 275 mm and 325 mm.

[0045]

[0087] Figure 5 shows a rear view of vehicle 100. Vehicle 100 has an overall width of 340. In one embodiment, the overall width 340 has a value of approximately 3,353 mm. In other embodiments, the overall width 340 can have any value within the range of approximately 3,000 to 4,000 mm.

[0046]

[0088] Figure 6 is a schematic diagram of the vehicle 100 in a turning position. In particular, the first frame section 122 is angled relative to the second frame section 124 at an angle 370. In one embodiment, the angle 370 has a value of approximately 45 degrees. In other embodiments, the angle 370 can have any value within the range of approximately 35 to 55 degrees. Furthermore, the inner turning path has a radius 372. The outer turning path has a radius 374. In one embodiment, the radius 372 has a value of approximately 4,363 mm. Also in one embodiment, the radius 374 has a value of approximately 9,065 mm. Of course, the angle 370, the radius 372, and / or the radius 374 can be changed in other embodiments as the length and / or width of the vehicle is changed, and / or as other features (such as the mechanical connection between the first frame section 122 and the second frame section 124) are changed.

[0047]

[0089] The design of vehicle 100 allows for improved visibility compared to other transport trucks. Referring to Figure 4, the driver's cab 116 is positioned very close to the foremost edge 319 of vehicle 100. This means that the occupants in the driver's cab 116 have virtually no restriction on their view from the forward window 123 of the driver's cab 116 (see Figure 1). This improved line of sight can help the driver have a better view of the battery assembly on the ground when a battery change is necessary.

[0048]

[0090] Vehicle 100 may be characterized not only by its envelope but also by its footprint. The envelope is a two-dimensional and three-dimensional representation of the vehicle's shape factors. As used herein, the term “vehicle footprint” is equal to the product of the vehicle’s overall length and overall width. Furthermore, the term “vehicle envelope volume” is equal to the product of the vehicle’s footprint and overall height.

[0049]

[0091] As can be seen in Figure 7, the vehicle 100 has a vehicle footprint 500. The vehicle 100 also has a vehicle envelope volume 502. In one embodiment, the vehicle footprint 500 is approximately 34 m². 2 It has the value of . Similarly, the vehicle envelope volume 502 is approximately 75 m 3 It has the value of . Of course, in other embodiments, both the footprint and envelope volume can be changed by changing one or more of the overall length, overall width, or overall height of the vehicle 100. In some other embodiments, the footprint of the vehicle is approximately 32-36 m 2 It may have any value within the range. Also, the vehicle's envelope volume is approximately 70-80 m³. 3 It can have any value within the range.

[0050]

[0092] For reference, vehicle 100 can be characterized as having an exterior surface. The exterior surface includes a front exterior surface 610 and a side exterior surface 612.

[0051]

[0093] As can be seen in Figure 7, the battery assembly 104 is positioned at the front corner of the vehicle 100. Specifically, the outer cage 601 (i.e., housing) of the battery assembly 104 is positioned at the first front corner 602, opposite to the second front corner 604 where the driver's cab 116 is located. Furthermore, when the battery assembly 104 is mounted on the vehicle 100, it forms part of both the front surface 610 and the first side surface 612 (i.e., the surface opposite the second side surface 614 adjacent to the driver's cab 116) of the vehicle 100. Specifically, the front wall 620 of the cage 601 forms part of the front outer surface 610, and the first side wall 622 of the cage 601 forms part of the side outer surface 614.

[0052]

[0094] In addition, the battery assembly 104 forms a portion of the upper outer surface 616 of the vehicle 100. Specifically, the top or wall 624 of the cage 601 forms a portion of the top outer surface 616. Furthermore, in some cases, the bottom or wall 626 of the cage 601 forms a portion of the bottom outer surface of the vehicle 100 (not visible in Figure 7).

[0053]

[0095] When the battery assembly 104 is removed, a large space 630 or gap may be formed along the front surface 610 of the vehicle 100 adjacent to the cab 116, as seen in Figure 8. Furthermore, the front end of the vehicle 100 may now have an L-shaped geometry with the cab 116 extending forward, isolated from the rest of the vehicle chassis. Thus, since the walls of the battery assembly form part of the outer surface of the vehicle when mounted, the geometric shape of its outer surface changes when the battery assembly is removed from the vehicle 100.

[0054]

[0096] By positioning the primary battery assembly on the exterior of the vehicle 100, battery installation and removal may be easier compared to electric vehicles with internally positioned batteries. Furthermore, the battery cage can simultaneously provide structural support for housing the battery pack, and can also provide structural support on the exterior of the vehicle.

[0055]

[0097] To contextualize the shape factors, weight, and other characteristics of vehicle 100, several benchmark vehicles are considered. These include a relatively large-capacity (39 metric tons) above-ground truck and a relatively small-capacity (30 metric tons) underground truck.

[0056]

[0098] Figures 9 to 11 show vehicle 100 (Figure 9), vehicle 700 (Figure 10), and vehicle 800 (Figure 11), respectively, and their corresponding carrying capacities. In addition, the table in Figure 12 shows the various dimensions of these vehicles. As can be seen by comparing vehicle 100 with the standard vehicle 700 and standard vehicle 800 in Figures 9 to 12, vehicle 100 has the same size and carrying capacity as these two diesel vehicles. That is, although vehicle 100 is a zero-emission electric truck, it is still possible to achieve the carrying capacity of a diesel vehicle of similar size.

[0057]

[0099] The standard vehicle 700 is intended to represent a mining vehicle capable of moving underground. As shown in the table in Figure 12, the standard vehicle 700 can have similar overall shape factors to vehicle 100. Specifically, as shown in Figure 12, the standard vehicle 700 can have a length of 10,118 mm, a width of 2,690 mm, and a height of 2,547 mm. These relatively small shape factors, particularly the overall height, allow the standard vehicle 700 to transport cargo through mining tunnels. An example of a mining vehicle with similar specifications to the standard vehicle 700 is Caterpillar's AD30 underground mining truck.

[0058]

[0100] The standard vehicle 800 is intended to represent a mining vehicle with the same carrying capacity as vehicle 100. Specifically, the standard vehicle 800 has a carrying capacity of 39 metric tons. An example of a mining vehicle with similar specifications to the standard vehicle 800 is the Volve A40G articulated transport truck.

[0059]

[0101] As shown in the table in Figure 12, the reference vehicle 800 may have shape factors that are slightly larger than those of vehicle 100. Specifically, as shown in Figure 12, the reference vehicle 800 may have a length of 11,263 mm, a width of 3,403 mm, and a height of 3,132 mm.

[0060]

[0102] To understand the power-to-weight ratio of vehicle 100, a comparison of weight and power is shown in Figures 13 and 14. Figure 13 is a schematic diagram of a chart showing the weights of three transport trucks. For reference, the towing weight of each vehicle is shown next to the empty working weight. Here, the towing weight is equal to the transport capacity when the transport capacity is measured by weight (not volume). As can be seen in Figure 13, the standard vehicle 700 has an empty weight of approximately 28.9 metric tons. The standard vehicle 700 has a towing weight of approximately 30 metric tons. The standard vehicle 800 has an empty weight of approximately 29.8 metric tons. The standard vehicle 800 has a towing weight of approximately 39 metric tons.

[0061]

[0103] As can be seen in Figure 13, vehicle 100 has an empty weight of approximately 45.4 metric tons. Vehicle 100 has a towing weight of approximately 40 metric tons. Therefore, it can be seen that vehicle 100 is substantially heavier than both standard vehicle 700 and standard vehicle 800.

[0062]

[0104] If the vehicle's weight increases, handling may be impaired if the power output is not increased. In this exemplary embodiment, increasing the weight of vehicle 100 compared to the reference vehicle can be achieved by increasing the overall power output.

[0063]

[0105] Figure 14 is a schematic diagram showing the output generated by various vehicles. As discussed earlier, one embodiment of vehicle 100 includes a set of electric motors operating at a continuous power in the range of approximately 400–500 kilowatts. In some cases, vehicle 100 can operate at a peak power in the range of approximately 500–600 kilowatts. In contrast, a standard vehicle 700 with a carrying capacity of 30 metric tons can only operate at a peak output of 305 kilowatts. Furthermore, a standard vehicle 800 with a carrying capacity of 39 metric tons can only operate at a peak output of 350 kilowatts.

[0064]

[0106] Figure 15 is a schematic diagram of a chart showing the power-to-weight ratio of several vehicles. As can be seen in Figure 15, vehicle 100 has a power-to-weight ratio of approximately 0.012 kg / m 3 Vehicle 700 has a power-to-weight ratio of approximately 0.010 kilograms per cubic meter. Vehicle 800 has a power-to-weight ratio of approximately 0.012 kilograms per cubic meter. Thus, it can be seen that these vehicles have approximately similar vehicle-to-weight ratios. Despite being significantly heavier than the other reference vehicles, vehicle 100 may have similar driving performance, as indicated by its equivalent power-to-weight ratio.

[0065]

[0107] Battery replacement method

[0108] It is desirable to have a system that can efficiently replace a discharged battery with a fully charged battery, preventing the vehicle from idling for extended periods while waiting for recharging.

[0066]

[0109] Some systems for replacing batteries in electric vehicles require substantial infrastructure. Because electric vehicle batteries tend to be large and heavy, battery replacement systems may include cranes, forklifts, loading ramps, pallets, or other components for lifting, lowering, and transporting batteries from the vehicle. Given the highly confined space within mines (e.g., underground shafts), it is desirable to have a battery replacement system that limits the amount of infrastructure required.

[0067]

[0110] Some embodiments can utilize so-called "zero-infrastructure" battery swapping systems. In such zero-infrastructure systems, only "space and dirt" is required to remove a discharged battery and re-install a fully charged battery.

[0068]

[0111] In some embodiments, the vehicle 100 is configured to have all the necessary equipment for removing a discharged battery and installing a fully charged battery located on the ground in the mine. Such equipment may include a removal system 250 for the primary battery assembly 104. These devices may also include a separate "tramming" battery (i.e., an auxiliary battery pack 105) used to supply power to the vehicle 100 when the primary battery assembly 104 is removed.

[0069]

[0112] Figures 16 to 27 show schematic diagrams of the process of replacing a battery assembly with a discharged battery pack with another battery assembly with a charged battery pack in a mining vehicle.

[0070]

[0113] As can be seen in Figure 16, vehicle 100 is traveling through the mining area. For illustrative purposes, a display screen 2000 that can provide information about the operating status of vehicle 100 is shown. It should be understood that some embodiments of vehicle 100 may be provided with a display, while other embodiments may not include a display. Yet another embodiment may include a display that shows different types of information. Furthermore, yet another embodiment may utilize any other type of indicator (lights, sound, etc.) to provide the driver with information about the operating status of vehicle 100.

[0071]

[0114] The display screen 2000 includes a battery charging unit 2002. The battery charging unit 2002 may include a first charging indicator 2004 that indicates the charging level for the battery pack, which includes the primary battery assembly 104. The battery charging unit 2002 may also include a second charging indicator 2006 that indicates the charging level for the auxiliary battery pack 105.

[0072]

[0115] The display screen 2000 may also include a power flow section 2010. The power flow section 2010 may provide schematic diagrams of several components related to the vehicle 100 and the propulsion system. The power flow section 2010 may include schematic diagrams of the first battery pack 200, the second battery pack 202, and the auxiliary battery pack 105. Furthermore, the power flow section 2010 may include schematic power flow lines 2020 indicating which battery pack is currently supplying power to the vehicle. For illustrative purposes, the power flow lines 2020 are shown flowing to each of the four wheels of the vehicle 100. However, it can be understood that the power flow actually flows from one or more battery packs to each of the four electric motors (i.e., the motor set 188 shown in Figure 3). Each motor then drives the corresponding wheel.

[0073]

[0116] As can be seen in Figure 16, the first charge indicator 2004 indicates that the battery pack of the primary battery assembly 104 has a low charge. To rectify this, the driver of the vehicle 100 moves the vehicle 100 towards an open area where a fully charged battery assembly 2040 (i.e., an assembly with a fully charged battery pack) is located. However, before installing the new battery assembly, the vehicle 100 moves to location 2032 adjacent to the charged battery assembly 2040. At location 2032, the vehicle 100 can automatically remove the discharged battery assembly 104.

[0074]

[0117] Figure 17 shows a schematic diagram of vehicle 100 approaching a predetermined location 2032 for the removal, i.e., "dropping," of the primary battery assembly 104. For reference, schematic lines indicate the approximate stopping point 2034 where vehicle 100 (e.g., the front end of vehicle 100) should be positioned to ensure that the primary battery assembly 104 is removed at the desired location. In some cases, it may not be necessary to identify the exact location where vehicle 100 should be positioned before removing the primary battery assembly 104, such as a completely open area without infrastructure. However, in some other embodiments, where the battery assembly may be dropped onto a pallet or other local structure (e.g., part of a charging bay or station), it may be necessary to position vehicle 100 in a precise location (and precise orientation) before removing the battery assembly.

[0075]

[0118] In Figure 18, it can be seen that the vehicle 100 is positioned at a stopping point 2034, allowing the primary battery assembly 104 to be removed. Before removing the battery, one or more physical connections between the primary battery assembly 104 and other components of the vehicle 100 can be disconnected. As an example, Figure 18 includes a schematic close-up of a single electrical cable 2050 disconnected from the battery pack 200 of the battery assembly 104. Similarly, an electrical cable 2052 is shown disconnected from the battery pack 202.

[0076]

[0119] In one exemplary embodiment, each battery pack of the primary battery assembly 104 may be disconnected from one or more electrical circuits of the vehicle 100. Such electrical circuits may be circuits that conduct power between one or more batteries and one or more motors. In one embodiment, each battery pack is connected to one or more electrical circuits by at least one cable. Therefore, to electrically disconnect each battery pack, one or more cables must be cut.

[0077]

[0120] In an exemplary embodiment, each battery pack may also be connected to a tube that carries fluid between the battery and the vehicle 100. For example, in some embodiments, oil for cooling can be carried through the battery. In such embodiments, the tubes connected to one or more fluid ports of the battery pack should also be disconnected before removing the battery assembly. Alternatively, in other embodiments, the tubes used for fluid cooling may be attached only when the battery pack is removed (for example, they may be cooled during charging).

[0078]

[0121] In different embodiments, the cutting of cables and / or tubes can be done manually or automatically. In some embodiments, before removing the primary battery assembly, the vehicle driver can exit the cab and walk to the opposite side of the vehicle where the primary battery assembly is located. The driver can then manually cut the electrical cables, as well as the fluid tubes. Alternatively, it should be understood that in some other embodiments, the electrical connections (and / or fluid connections) can be automatically disconnected.

[0079]

[0122] Once the necessary disconnection is made between the battery assembly 104 and the vehicle 100, the battery assembly 104 can be removed. Figures 19 and 20 show the sequential steps of removing the primary battery assembly 104 using the removal system 250. In particular, the battery assembly 104 is seen in a partially lowered position 2070 in Figure 19. The battery assembly 104 is also seen in a fully lowered position 2062 in Figure 20.

[0080]

[0123] As can be seen in Figures 19-20, the battery assembly 104 is lowered using the linkage assembly of the detachable system 250. Specific designs of the linkage assembly that may be used are discussed in more detail below and are shown, for example, in Figure 32.

[0081]

[0124] Since the battery assembly 104 must be disconnected from any motor of the vehicle 100 before removal, the detachment system 250 may require power from the auxiliary battery pack 105. That is, any power required to operate the linkage assembly 252 or other components of the detachment system 250 may be supplied by the auxiliary battery pack 105.

[0082]

[0125] In an alternative embodiment, the electrical cables may be designed to extend from the vehicle 100 as the battery assembly 104 is lowered to the ground. In such an embodiment, the electrical cables can remain attached to the battery pack of the primary battery assembly 104 when removal is performed. Thus, it is conceivable that the power from the first battery pack 200 and / or the second battery pack 202 can be used to power the removal system 250.

[0083]

[0126] In some embodiments, after the primary battery assembly 104 has descended, the driver may be given the option to plug in one or both battery packs for recharging. For example, in one embodiment, one or more long charging cables may be found near location 2032 (see Figure 18). The charging cables may be connected to a power source located elsewhere in the mine (or outside the mine).

[0084]

[0127] In another embodiment, battery replacement may be performed adjacent to one or more recharging stations. In such an embodiment, the battery may be removed at a location directly adjacent to the recharging station.

[0085]

[0128] In yet another embodiment, the batteries do not need to be recharged at the exchange site, but may be moved to another location for charging. For example, in some embodiments, a crew member among the workers can collect discharged batteries throughout the mine and transport them to another location inside (or outside) the mine where charging facilities are provided. This same crew member could then deliver the recently charged batteries to locations throughout the mine where transport trucks or other electric mining vehicles are expected to be operating.

[0086]

[0129] Figure 21 shows the vehicle 100 backing away from the battery assembly 104. As will be described in more detail below, the removal system 250 can be configured to automatically detach from the battery assembly 104 when the battery assembly 104 is moved to its lowest position. In particular, the driver does not need to manually remove the battery assembly 104 from the removal system 250. This can help save time during the replacement process by reducing the number of times the driver has to enter and exit the driver's cab throughout the process.

[0087]

[0130] Figure 22 shows that vehicle 100 moves from a first location 2032 adjacent to a discharged battery assembly 104 to a second location 2033 adjacent to a fully charged battery assembly 2040. Display screen 2000 shows that as vehicle 100 moves between the first and second locations, vehicle 100 is powered by the auxiliary battery pack 105. This is indicated by a lower charge level (compared to the charge level shown in Figure 16) shown by the second charge indicator 2006. In addition, the power flow unit 2010 explicitly shows that power is flowing from the auxiliary battery pack 105 to the wheels (via electric motors positioned adjacent to each wheel).

[0088]

[0131] The embodiment shown in Figure 22 depicts power flowing to all four wheels, but in some embodiments, the auxiliary battery pack 105 can supply power to only some of the wheels. In one embodiment, the auxiliary battery pack 105 can supply power to only the front wheels. In another embodiment, the auxiliary battery pack 105 can supply power to only the rear wheels. Therefore, in some cases, the vehicle 100 can operate in either front-wheel drive or rear-wheel drive mode while the battery is being replaced.

[0089]

[0132] Figure 23 shows a schematic diagram of vehicle 100 approaching a fully charged battery assembly 2040. In some embodiments, vehicle 100 may include equipment to assist in aligning vehicle 100 with the battery assembly 2040. In one embodiment, vehicle 100 may include one or more cameras positioned on or near the attachment / detachment system 250. As vehicle 100 approaches, the driver can view a video feed display to help align the attachment / detachment system 250 with the battery assembly 2040.

[0090]

[0133] Referring to Figure 23, a schematic diagram of the second display screen 2100 is shown. The display screen 2100 may, for example, display the view from a mounted camera that may be located in part of the attachment / detachment system 250.

[0091]

[0134] In some embodiments, markings or other visual indicators can be incorporated on the battery assembly. These markings can be viewed on the video feed to help the driver identify when the vehicle is properly aligned. In the embodiment of Figure 23, the rear side of the battery assembly 2040 may be configured to have a first physical indicator 2105 and a second physical indicator 2107 on the top and bottom of the battery assembly 2040, respectively. A set of virtual indicators, including a first virtual indicator 2110 and a second virtual indicator 2111, is superimposed on a video image of the battery assembly 2040. As the driver approaches the battery assembly 2040, he (or she) may attempt to steer the vehicle 100 so that the virtual indicators 2110 and 2111 align with the physical indicators 2105 and 2107, respectively. This can help the driver accurately align the components of the attachment / detachment system 250 with the corresponding features of the battery assembly 2040 (such as a grippable bar).

[0092]

[0135] Figure 24 shows a schematic diagram of vehicle 100 parked at a second location 2033 where a charged battery assembly 2040 is located. The vehicle 100 is positioned so that the attachment / detachment system 250 is in contact with the charged battery assembly 2040.

[0093]

[0136] Figure 25 shows a schematic diagram of the vehicle 100 when the charged battery assembly 2040 is lifted off the ground by the removal system 250. Finally, as seen in Figure 26, the battery assembly 2040 is lifted to its final mounting position. At this point, the driver may reconnect the electrical cables and / or other physical connections to the battery packs of the battery assembly 2040. As seen in Figure 26, cables 2050 and 2052 are manually reconnected to the battery packs 2060 and 2062 of the battery assembly 2040, respectively.

[0094]

[0137] In an alternative embodiment, the electrical cables may be designed to extend from the vehicle 100 while the battery assembly 2040 is positioned on the ground. In such an embodiment, the electrical cables can be attached to the battery pack of the battery assembly 2040 before the battery assembly 2040 is mounted on the vehicle 100. Thus, it is conceivable that the power from battery packs 2060 and 2062 can be used to power the mounting / detaching system 250.

[0095]

[0138] Figure 27 shows a schematic diagram of vehicle 100 moving away from (backing up from) the second location 2033 with a fully charged primary battery assembly. As can be seen in the power flow section 2010 of display screen 2000, battery packs 2060 and 2062 of the primary battery assembly 2040 are supplying power to the movement of vehicle 100, and the auxiliary battery packs are no longer in use.

[0096]

[0139] Vehicle 100 can now return to material transport inside (or outside) the mine, as long as the current primary battery assembly remains charged. When the current battery assembly is completely (or nearly completely) discharged, vehicle 100 can repeat this same process of replacing the discharged battery with a fully charged battery.

[0097]

[0140] Figure 28 is a flowchart showing the process for battery replacement according to the steps described above. It should be understood that in some embodiments, some of these steps may be optional. In other embodiments, additional steps may be included.

[0098]

[0141] During the first step 2300, a vehicle having one or more replaceable battery packs comprising the first battery assembly may move to the first location. In some cases, the first location may be adjacent to a second location where a second battery assembly comprising one or more charged battery packs is located.

[0099]

[0142] In the second step 2302, one or more battery packs of the first battery assembly can be disconnected from the vehicle. This may include cutting the power cables. In some cases, the power cables may be cut manually. In other cases, the power cables can be cut automatically.

[0100]

[0143] In the third step 2304, the first battery assembly can be removed from the vehicle using an on-board removal system. In some cases, this may include a hydraulically operated linkage assembly as well as one or more latches. In particular, in some cases, the latches holding the first battery assembly in place relative to the vehicle are released, and the linkage assembly can be used to lower the first battery assembly to the ground. In some cases, once the battery assembly is on the ground, the linkage system automatically disengages from the first battery assembly.

[0101]

[0144] In the fourth step 2306, the vehicle can move away from the first battery assembly to a second location where the second battery assembly is located. During this time, the vehicle can operate using power from the auxiliary battery that is always installed in the vehicle.

[0102]

[0145] In the fifth step 2308, the vehicle can approach the second battery assembly and make contact between the second battery assembly and the attachment / detachment system. In some cases, a video feed can be used to help properly align the attachment / detachment system with the second battery assembly. In some cases, markings can be provided on the battery assembly to facilitate alignment. In other cases, the video feed may project one or more markings that are aligned with parts of the battery assembly (possibly other physical markings on the battery).

[0103]

[0146] In the sixth step 2310, the second battery assembly can be lifted and locked in place in the vehicle using the attachment / detachment system. In some cases, once the second battery assembly is lifted to its highest position, one or more portions of the battery assembly may be gripped by one or more latches of the attachment / detachment system to lock the battery assembly in place.

[0104]

[0147] In step 7, 2312, once the second battery assembly is installed in the vehicle, any power cables can be reconnected to the battery pack of the second battery assembly. At this point, the vehicle may be powered by the second battery assembly rather than the auxiliary battery.

[0105]

[0148] In some embodiments, battery replacement can be performed at one or more fixed locations (e.g., locations within the mine). In such cases, the driver may have a map or list of these locations, and when the primary battery assembly needs to be replaced, the driver can drive the vehicle to the nearest known replacement location. In other embodiments, the battery replacement locations may change, particularly as mining operations progress with vehicles that are primarily located in some areas of the mine but not others. In yet another embodiment, battery replacement may be performed on demand. That is, when the driver recognizes that the battery assembly is low on charge, they can call a dispatcher and request that a fully charged battery assembly be delivered to a nearby location.

[0106]

[0149] This embodiment demonstrates battery replacement in an unloaded vehicle. However, it will be understood that this same battery replacement process can occur while materials are loaded on the truck bed.

[0107]

[0150] The embodiments may include equipment for recharging the auxiliary battery pack. In some embodiments, the auxiliary battery pack may be charged by an onboard converter connected to one or more modules of the primary battery assembly. In one embodiment, an onboard 600V to 300V DC / DC converter can be used. In other embodiments, the auxiliary battery pack can be recharged by an external source. In such cases, the auxiliary battery pack can be recharged at the end of the day (or other operating cycle of the truck).

[0108]

[0151] Battery removal and installation

[0152] Figures 29–31 show schematic diagrams of an exemplary battery assembly 3000. Battery assembly 3000 may share some equipment with battery assembly 104 (and battery assembly 2040). However, it can be understood that in different embodiments, some of the following features of the battery assembly may be optional.

[0109]

[0153] Referring to Figures 29-30, the battery assembly 3000 consists of a battery cage 3002, a first battery pack 3004, and a second battery pack 3006. Each battery pack may further have one or more battery cells.

[0110]

[0154] The battery cage 3002 may serve to hold and protect the first battery pack 3004 and the second battery pack 3006. For this purpose, the battery cage 3002 may be sized and dimensional to accommodate each of the first battery pack 3004 and the second battery pack 3006. In the embodiments shown in Figures 29-30, the battery cage 3002 is configured as a relatively thin outer casing with an internal cavity capable of holding the two battery packs in a stacked configuration. In particular, the battery cage 3002 has a horizontal footprint slightly larger than the horizontal footprint of each battery pack. The battery cage 3002 also has a vertical height slightly larger than the combined height of the first battery pack 3004 and the second battery pack 3006.

[0111]

[0155] As shown in Figure 30, the battery cage 3002 is composed of two separate, separable parts, including an upper cage portion 3010 and a lower cage portion 3012. The upper cage portion 3010 is sized and dimensional to accommodate a first battery pack 3004. The lower cage portion 3012 is sized and dimensional to accommodate a second battery pack 3006. The upper cage portion 3010 and the lower cage portion 3012 can be attached using any type of fastener known in the art.

[0112]

[0156] The battery cage 3002 may include equipment for facilitating attachment and detachment. Some embodiments may include one or more horizontal bars configured to facilitate installation. Some embodiments may include one or more vertical bars configured to facilitate installation. Some embodiments may include a combination of horizontal and vertical bars to facilitate installation.

[0113]

[0157] As shown in Figures 29-31, the battery cage 3002 includes a set of horizontal mounting bars, including an upper horizontal mounting bar 3022 and a lower horizontal mounting bar 3024.

[0114]

[0158] Each horizontal mounting bar protrudes slightly rearward from the rear side 3015 of the battery cage 3002. Furthermore, the horizontal mounting bars are held in place by two pairs of vertically oriented brackets 3030. These vertically oriented brackets 3030 are positioned at the ends on both sides of the horizontal mounting bars. Each pair of brackets may be spaced a fixed distance apart. As an example, the first vertically oriented bracket 3031 and the second vertically oriented bracket 3032 are spaced a distance of 3040 (see Figure 31). This configuration divides each horizontal bar into separate sections that can be gripped by the attachment system. Specifically, the upper horizontal mounting bar 3022 is divided into a first end segment 3050, an intermediate segment 3052, and a second end segment 3054. Similarly, the lower horizontal mounting bar 3024 is divided into a first end segment 3060, an intermediate segment 3062, and a second end segment 3064.

[0115]

[0159] Some embodiments may include one or more vertical bars. As can be seen in Figures 29 to 31, the battery cage 3002 includes a set of vertical mounting bars. In particular, the battery cage 3002 comprises a first vertical mounting bar 3072 and a second vertical mounting bar 3074.

[0116]

[0160] Each vertical mounting bar extends from the underside of the lower cage portion 3012 to the underside of the upper cage portion 3010. Furthermore, vertical mounting bars are positioned at the rear corners on both sides of the battery cage 3002. Therefore, in some cases, each vertical mounting bar may be configured to provide some degree of strength to the battery cage 3002 under vertically applied loads. In some cases, similar vertically oriented bars may be positioned at one or both of the front corners of the battery cage 3002 to provide structural support.

[0117]

[0161] It can be understood that both horizontal and vertical bars can be facilitated in at least three ways. First, either type of bar can be gripped by components of the attachment / detachment system to assist in raising and / or lowering the battery assembly. Second, either type of bar can facilitate horizontal and / or vertical alignment by interacting with corresponding components of the attachment / detachment system (e.g., a V-shaped block that can help automatically align the battery cage horizontally and / or vertically). Finally, either type of bar can be locked in place, for example, using one or more latches or other locking mechanisms. In different embodiments, it can be understood that horizontal and vertical bars may be used to achieve different functions (e.g., a horizontal bar for lifting, aligning, and latching, and a vertical bar for aligning and latching, but not for lifting).

[0118]

[0162] In the embodiment shown in Figures 29 to 31, the horizontal mounting bar assembly 3020 may function as a contact point for lifting / lowering the battery cage 3002, aligning the battery cage 3002, and locking the battery cage 3002 in place (for example, using a latch that grips the bar). In contrast, the vertical mounting bar assembly 3070 may not be used as a contact point while lifting / lowering the battery cage 3002, but may be used to facilitate aligning and / or locking the battery cage 3002 in place (for example, using a latch that grips the bar).

[0119]

[0163] The battery cage 3002 may be closed primarily on the front, top, bottom, and sides. However, the battery cage 3002 may be partially open on the rear 3015 (and part of the sides) to expose the battery pack connection ports or other equipment.

[0120]

[0164] Some embodiments may include equipment to facilitate sliding the battery on an uneven ground surface. As best shown in Figure 31, the battery cage 3002 may have a bottom surface 3005 with rounded corners 3007 to facilitate sliding.

[0121]

[0165] The battery cage 3002 is designed to hold and protect the first battery pack 3004 and the second battery pack 3006. To do this, the battery cage 3002 is configured to have sufficient strength while being secured to the transport truck, mainly along the mounting points on the rear side 3015.

[0122]

[0166] In different embodiments, the material of the battery cage 3002 can be varied. In some embodiments, the battery cage 3002 is made of a material including metal or a metal alloy. In some embodiments, the battery cage 3002 is made of a material similar to the material used in the chassis of the vehicle 100 (e.g., frame 101).

[0123]

[0167] Each battery pack may be configured to have one or more ports for receiving electrical cables. As seen in Figure 31, the first battery pack 3004 includes a port 3090 for connecting an electrical cable. The second battery pack 3006 includes a port 3092 for connecting an electrical cable. These ports may be used to connect each battery pack to one or more circuits in the vehicle when the battery assembly 3000 is installed in the vehicle. These ports may also be used to connect each battery pack to a charging source when the battery assembly is removed from the vehicle. However, in other embodiments, each battery pack may include two or more electrical ports, including a port for connecting the battery pack to the vehicle's electrical circuit and a separate port for charging the battery pack.

[0124]

[0168] Each battery pack may also be configured to include one or more valves or fluid ports to facilitate the flow of oil or other fluids for cooling the battery pack. In Figure 31, the first battery pack 3004 includes a set of fluid ports 3096. The second battery pack 3006 also includes a set of fluid components 3098.

[0125]

[0169] Figure 32 shows a schematic diagram of a portion of the vehicle 100 at the front end 90. As can be seen in Figure 32, the detachable system 250 is located at the front end 90 adjacent to the driver's cab 116. The detachable system 250 comprises a pair of link mechanism assemblies 3100. Specifically, the detachable system 250 includes a first link mechanism assembly 3102 and a second link mechanism assembly 3104 spaced apart from the first link mechanism assembly 3102.

[0126]

[0170] Each linkage assembly is actuated by at least one hydraulic cylinder. Specifically, the first linkage assembly 3102 is actuated by the first hydraulic cylinder 3110. The second linkage assembly 3104 is actuated by the second hydraulic cylinder 3112.

[0127]

[0171] The detachable system 250 may also include equipment for securing the battery assembly in place on the vehicle 100. The detachable system 250 includes a set of receiving members 3199 that can be used to secure the battery assembly in place on the vehicle 100.

[0128]

[0172] Figure 33 is an exploded perspective view of the first linkage assembly 3102 (also simply called the linkage assembly 3102), the hydraulic cylinder 3110, and another structural element 3111. The first end of the structural element 3111 may be pivotably connected to the cylinder barrel 3114 of the hydraulic cylinder 3110. In some embodiments, the second end of the structural element 3111 may be attached to another part of the vehicle 100. In some embodiments, the second end of the structural element 3111 may be fixed to one of the links in the linkage assembly 3102.

[0129]

[0173] The link mechanism assembly 3102 may be a four-bar linkage mechanism. That is, the link mechanism assembly 3102 comprises four links arranged in a loop and connected to each other by four rotary joints. More specifically, the link mechanism assembly 3102 may be a planar four-bar linkage mechanism, since the links are confined to move within a parallel plane.

[0130]

[0174] The linkage assembly 3102 comprises four links, including a ground link 3121 (also called a fixed link or frame), an upper ground link 3122, a lower ground link 3123, and a floating link 3124. As seen in Figure 32, the ground link 3121 may be fixed in a substantially vertical position on the vehicle 100. The floating link 3124 remains substantially parallel to the ground link 3121 (i.e., oriented substantially vertically). The orientation of the upper ground link 3122 and the lower ground link 3123 may change when the linkage mechanism is in operation.

[0131]

[0175] The floating link 3124 includes a first hook 3140 and a second hook 3142. The first hook 3140 and the second hook 3142 extend forward from the floating link 3124 so that when positioned on the vehicle 100, the hooks may be at the foremost part of the link mechanism assembly 3102. The first hook 3140 may be positioned above the second hook 3142. That is, the first hook 3140 and the second hook 3142 may have different vertical positions. The first hook 3140 may be positioned directly below the pivot joint 3147 between the upper ground link 3122 and the floating link 3124. Similarly, the second hook 3142 may be positioned directly below the pivot joint 3149 between the lower ground link 3123 and the floating link 3124.

[0132]

[0176] Each hook is shaped and designed to receive a corresponding portion of the battery cage so that the link mechanism assembly 3102 can engage with the battery cage together with the second link mechanism assembly 3104 to lift (or lower) it. For example, the first hook 3140 may be sized and shaped to receive a segment of the upper horizontal mounting bar 3022. The second hook 3142 may be sized and shaped to receive a segment of the lower horizontal mounting bar 3024.

[0133]

[0177] The linkage assembly 3102 is actuated by the piston rod 3115 of the hydraulic cylinder 3110. Specifically, the end of the piston rod 3115 may be pivotably coupled to the end 3129 of the upper ground link 3122. The end 3129 may also be the end of the upper ground link 3122 connected to the ground link 3121. Thus, when the piston rod 3115 extends from the cylinder barrel 3114, the end 3129 of the upper ground link 3122 is pushed downward, acting to tilt the upper ground link 3122 upward, and as a result the floating link 3124 is lifted upward. Similarly, when the piston rod 3115 retracts within the cylinder barrel 3114, the end 3129 of the upper ground link 3122 is pulled up, acting to tilt the upper ground link 3122 downward, and as a result the floating link 3124 is lowered. Due to this configuration of the link mechanism assembly 3102, the lower ground link 3124 does not necessarily need to be in direct contact with the actuator (such as the hydraulic cylinder 3110) during operation, but moves in a similar manner to the upper ground link 3122.

[0134]

[0178] While this embodiment incorporates a linkage assembly, it will be understood that in other embodiments, other mechanical assemblies may be used to raise and lower the battery assembly. More broadly, the battery loading / unloading system may include an operable assembly (e.g., a linkage assembly and a hydraulic cylinder) and an actuator for moving the operable assembly. The system may further include an engaging component (e.g., a floating link) on the operable assembly. The engaging component may include at least two vertically spaced hooks for engaging with the battery assembly so that the battery assembly can be raised or lowered when the operable assembly is operated.

[0135]

[0179] It should also be understood that the term “hook” as used herein is not intended to be limited to any particular size or shape. As used herein, a hook refers to any piece of material (e.g., metal) that is curved or bent for the purpose of holding, capturing, or otherwise engaging with another element.

[0136]

[0180] Figures 34 to 38 show schematic diagrams of the range of motion of the link mechanism assembly 3102. For clarity, the overall position of the floating link 3124 is referenced, as well as the vertical and horizontal components of that overall position. The vertical component of the position may be considered relative to an element with a fixed vertical position, such as structural element 3111. Similarly, the horizontal component of the position may be considered relative to an element with a fixed horizontal position, such as ground link 3121.

[0137]

[0181] First, as can be seen in Figure 34, the link mechanism assembly 3102 is positioned in a first position corresponding to a first vertical position and a first horizontal position. In this first position, the floating link 3124 is in its lowest vertical position within its range of motion. Also, the upper ground link 3122 and the lower ground link 3123 are inclined downward.

[0138]

[0182] Figure 35 shows the linkage assembly 3102 in a second position, corresponding to the second vertical and second horizontal positions. In this second position, both the upper ground link 3122 and the lower ground link 3123 are approximately horizontal (and therefore approximately perpendicular to the floating link 3124). As can be seen by comparing with Figure 34, the floating link 3124 has moved upward. The floating link 3124 has also achieved some small movement forward (for example, away from the ground link 3121). This initial sweeping forward movement of the floating link 3124 may help ensure proper engagement with the battery assembly, as will be further detailed below.

[0139]

[0183] Figure 36 shows the linkage assembly 3102 in a third position, which corresponds to a third vertical and a third horizontal position. In this third position, both the upper ground link 3122 and the lower ground link 3123 tilt upward so that the floating link 3124 is lifted. Compared to the second position in Figure 35, the floating link 3124 rises primarily vertically, with relatively little horizontal movement. This helps ensure that the energy used to lift the battery assembly onto the vehicle is used primarily for the vertical lift, rather than wasting energy moving the battery assembly through a wide range of horizontal motion as it is lifted off the ground.

[0140]

[0184] Figure 37 shows the link mechanism assembly 3102 in a fourth position, corresponding to a fourth vertical and a fourth horizontal position. In this fourth position, the upper ground link 3122 and the lower ground link 3123 are more severely inclined compared to their orientation in the third position shown in Figure 36. Moving from the third position to this fourth position, the floating link 3124 begins to reverse its horizontal movement, and as a result, now moves back toward the ground link 3121 (and vehicle 100). Furthermore, the velocity of the vertical movement between the third and fourth positions is less than the velocity of its horizontal movement.

[0141]

[0185] Figure 38 shows the linkage assembly 3102 in the fifth and final position, corresponding to the fifth vertical and fifth horizontal positions. In this fifth position, the upper ground link 3122 and the lower ground link 3123 are nearly perpendicular in their respective directions. The floating link 3124 is positioned directly adjacent to (and possibly in contact with) the ground link 3121. Between the fourth position in Figure 37 and this fifth position, almost all of the motion of the floating link 3124 is directed horizontally with minimal vertical movement. This helps ensure that the battery assembly has sufficient horizontal momentum to contact and engage with the locking mechanism (such as a latch).

[0142]

[0186] Although the above description is directed towards the first linkage assembly 3102, it can be understood that a similar setup applies to the second linkage assembly 3104. Furthermore, the first linkage assembly 3102 and the second linkage assembly 3104 are configured to act parallel to each other, undergo substantially identical motion, and share loads when the battery assembly is lifted or lowered from the vehicle.

[0143]

[0187] Figure 39 is a schematic diagram of the front end 90 of the vehicle 100 and the removed battery assembly 3000. As schematically shown in Figure 39, each hook of the attachment / detachment system 250 may correspond to one of the horizontal mounting bars of the battery cage 3002. That is, each hook may be configured to grip one of these two bars.

[0144]

[0188] The first hook 3140 of the first link mechanism assembly 3102 is positioned to engage with the upper horizontal mounting bar 3022. Similarly, the first hook 3180 of the second link mechanism assembly 3104 is also positioned to engage with the upper horizontal mounting bar 3022. The second hook 3142 of the first link mechanism assembly 3102 is positioned to engage with the lower horizontal mounting bar 3022. Similarly, the second hook 3182 of the second link mechanism assembly 3104 is also positioned to engage with the lower horizontal mounting bar 3024. This configuration provides four engagement points between the detachment system 250 and the battery assembly 3000.

[0145]

[0189] Generally, each hook can grip any segment of the corresponding horizontal bar. In some embodiments, it may be desirable for the hooks to grip intermediate segments of the bar, such as the intermediate segment 3052 of the upper horizontal mounting bar 3022 and the intermediate segment 3062 of the lower horizontal mounting bar 3024 (see Figure 31). In other embodiments, it may be desirable for the hooks to grip end segments of the bar. This includes the first end segment 3050 and the second end segment 3054 of the upper horizontal mounting bar 3022. This also includes the first end segment 3060 and the second end segment 3064 of the lower horizontal mounting bar 3024.

[0146]

[0190] Figures 40–45 show schematic diagrams of the battery assembly installation process. For clarity, only the first linkage assembly 3102 is shown in Figures 40–45, but it can be understood that the second linkage assembly 3104 may operate in substantially the same manner as the first linkage assembly 3102. Furthermore, portions of the battery assembly 3000 are indicated by dashed lines so that the sections of the upper horizontal mounting bar 3022 and the lower horizontal mounting bar 3024 are visible during this process.

[0147]

[0191] Initially, as shown in Figure 40, the battery assembly 3000 is positioned on the ground surface 3200. As the vehicle 100 approaches the battery assembly 3000 (for example, as shown in Figure 23), the linkage assembly 3102 may be in a lowered position. Specifically, the linkage assembly 3102 can be lowered to a position where the first hook 3140 is sufficiently lower than the upper horizontal mounting bar 3022 and the second hook 3142 is sufficiently lower than the lower horizontal mounting bar 3024. This ensures that when the hooks make contact with the rear side 3015 of the battery cage 3002 (as shown in Figure 41), the first hook 3140 and the second hook 3142 can be moved to a position just below the mounting bars.

[0148]

[0192] Once the first hook 3140 and the second hook 3142 make contact with the battery cage 3002, the hydraulic cylinder 3110 may actuate the linkage assembly 3102, as shown in Figure 42. As described above, starting from the lowest position, the linkage assembly 3102 moves slightly forward horizontally at the same time that the floating link 3124 begins to rise. This slight forward horizontal movement may have the effect of further pushing the first hook 3140 and the second hook 3142 into the battery cage 3002. In some cases, this force may cause the battery cage 3002 (or alternatively, the vehicle 100) to be slightly displaced horizontally or tilted slightly (as seen in Figure 42). However, this forward movement is intended to ensure that the first hook 3140 and the second hook 3142 fully engage with the upper horizontal mounting bar 3022 and the lower horizontal mounting bar 3024.

[0149]

[0193] As shown in Figure 42, with the system properly engaged with the mounting bar link mechanism, the link mechanism assembly 3102 can continue to move, as shown in Figure 43, with the floating link 3124 moving primarily vertically. As the floating link 3124 rises further, the battery assembly 3000 is lifted from the ground surface 3200.

[0150]

[0194] Ultimately, as shown in Figures 44-45, the motion of the linkage assembly 3102 is such that the battery assembly 3000 is primarily translated in the rearward direction. This helps ensure that the battery assembly 3000 has sufficient rearward momentum to engage and lock in place by a locking mechanism (e.g., a latch).

[0151]

[0195] It can be understood that the use of hooks at different vertical positions of the floating link 3120 helps to ensure the stability and proper loading of the battery assembly 3000. Specifically, using both the upper and lower sets of hooks (crossing both link mechanism assemblies) helps to maintain the battery assembly in a substantially constant orientation throughout the lifting process. For example, as shown in Figure 40, the central vertical axis 3210 of the battery cage 3002 is substantially parallel to the floating link 3120 (i.e., the central vertical axis 3212 of the floating link 3120) before engaging with the battery cage 3002. As the battery cage 3002 is lifted and moved both horizontally and vertically between its lowest position in Figure 42 and its highest position in Figure 45, the battery cage 3002 maintains a substantially constant orientation; that is, the central vertical axis 3210 remains substantially parallel to the floating link 3120. In other words, this means that the battery cage 3002 will not tilt or become unstable throughout the entire lifting process. This helps ensure that unwanted locking of the battery assembly 3000 does not occur, as such locking can reduce the efficiency of the lifting mechanism and make alignment between the battery assembly 3000 and any locking mechanism more difficult.

[0152]

[0196] It will be understood that the process described above in Figures 40-45 may be reversed in order to lower the battery assembly 3000 from the vehicle 100 to the ground surface 3200. Once the battery assembly 3000 is lowered to the ground surface 3200, the linkage assembly 3102 may be lowered until the first hook 3140 and the second hook 3142 are low enough to disengage from the upper horizontal mounting bar 3022 and the lower horizontal mounting bar 3024. Once the hooks are disengaged, the vehicle 100 may back away from the battery assembly 3000 to move to a location where another battery assembly can be mounted (for example, as shown in Figure 21).

[0153]

[0197] Figures 46–48 show schematic diagrams of an alternative embodiment of a system for raising and lowering a battery. In Figure 46, the battery 3300 is initially placed on the lifting platform 3302. A linkage assembly 3304 connects the upper central portion of the battery 3300 to the lifting platform 3302. As the linkage assembly 3304 rotates and extends, the battery 3300 is lifted off the platform 3302 and lowered to a position away from the platform 3302, as shown in Figures 47–48. However, as clearly shown in Figure 47, the battery 3300 may rock or oscillate as it descends due to the action that the battery is only engaged in a single vertical position.

[0154]

[0198] In mining environments, the ground surface may not be level. This means that when a vehicle attempts to install or remove a battery assembly, the patch of ground on which the battery rises (or falls) may be slightly higher or lower than the patch of ground on which the vehicle's wheels are located. Some embodiments of the vehicle may include equipment to enable the battery to be installed or removed on uneven ground.

[0155]

[0199] Figure 49 shows a schematic diagram of a portion of vehicle 100 for the purpose of characterizing the loading envelope of the vehicle 100's loading system 250. Here, the wheels of vehicle 100 are seated on a patch 3402 of ground. For reference, the height of the patch 3402 of ground is considered to be the ground level 3403. In an exemplary embodiment, the loading system 250 can load a battery assembly 3410 from a raised patch 3404 of ground. The patch 3404 of ground may be raised by a height of 3420 from the ground level 3403. In addition, the loading system 250 can load a battery assembly 3411 from a recessed patch 3406 of ground. The patch 3406 of ground may be recessed by a height of 3422 from the ground level 3403. For illustrative purposes, the raised patch 3404 and the recessed patch 3406 of ground are shown adjacent to each other.

[0156]

[0200] The overall vertical distance between the ground depression patch 3406 and the ground elevation patch 3404 is called the “loading envelope” of the detachment system 250. This distance is shown by the loading envelope 3424 in Figure 49 and is equal to the sum of heights 3420 and 3422.

[0157]

[0201] The size of the loading envelope may be determined by the range of motion of the linkage assembly of the detachable system 250, as well as the relative height of these assemblies from the ground level. Since the hooks must be lower than the horizontal mounting bar on the battery cage when they first engage with the battery cage, the minimum loading position is constrained by how low the hooks on each linkage assembly are relative to the ground level. In some cases, the highest loading position may be constrained by the height (relative to the ground level) at which the linkage assembly begins to retract backward, and therefore may not be able to engage with the horizontal mounting bar.

[0158]

[0202] In different embodiments, the minimum loading position, maximum loading position, and overall loading envelope values ​​may vary. In some embodiments, the minimum loading position may vary within a range of approximately 6 to 10 inches below ground level (which is defined by the height of the ground on which the front wheels are positioned). In one embodiment, the minimum loading position has a value of approximately 8 inches below ground level. In some embodiments, the maximum loading position may vary within a range of approximately 2 to 4 inches below ground level. In one embodiment, the maximum loading position has a value of approximately 2.75 inches above ground level.

[0159]

[0203] In some embodiments, it will be understood that there is a detachment system sufficient to lift a battery assembly weighing 8 to 10 kilograms. Therefore, it should be understood that the components of each linkage assembly can be designed with this constraint in mind.

[0160]

[0204] Battery automatic alignment and locking system

[0205] As described above, once the detachment system 250 lifts the battery assembly to the desired position on the vehicle, some mechanism can be used to lock the battery assembly in place on the vehicle. In addition, in some embodiments, the detachment system may also include equipment to assist in aligning the battery assembly. Such equipment may include an automatic alignment component that guides the battery assembly into place to ensure that the battery assembly can be properly engaged by one or more locking mechanisms (e.g., latches).

[0161]

[0206] Figure 50 is a schematic perspective view of the front end of the vehicle 100. Referring to Figure 50, the attachment / detachment system 250 can incorporate both autonomous alignment and locking features, which are sometimes collectively referred to as components of the alignment / locking system.

[0162]

[0207] Vehicle 100 may include a plurality of receiving members. The receiving members can be any components configured to receive and hold mounting bars or other mounting elements of a battery cage. In some embodiments, the receiving members may include alignment portions for guiding mounting bars or other elements into place. In some embodiments, the receiving members may also include locking mechanisms for locking mounting bars or other elements into place. Alternatively, in other embodiments, the receiving members may include only locking mechanisms and not alignment portions.

[0163]

[0208] Specifically, in Figure 50, the vehicle 100 includes a first receiving member 4011, a second receiving member 4012, a third receiving member 4013, a fourth receiving member 4014, a fifth receiving member 4015, a sixth receiving member 4016, a seventh receiving member 4017, and an eighth receiving member 4018, and these can be collectively referred to as multiple receiving members 4010. For illustrative purposes, the receiving members are schematically shown in Figure 50.

[0164]

[0209] The multiple receiving members 4010 may be divided into a set of receiving members configured to engage with the horizontal mounting bar of the battery assembly and another set of receiving members configured to engage with the vertical mounting bar of the battery assembly. Specifically, the first receiving member 4011, the second receiving member 4012, the third receiving member 4013, and the fourth receiving member 4014 collectively comprise the first set of receiving members 4020 configured to engage with the horizontal mounting bar. In addition, the fifth receiving member 4015, the sixth receiving member 4016, the seventh receiving member 4017, and the eighth receiving member 4018 collectively comprise the second set of receiving members 4030 configured to engage with the vertical mounting bar.

[0165]

[0210] The first support member set 4020 may be positioned on the vehicle 100 horizontally between the first link mechanism assembly 3102 and the second link mechanism assembly 3104. Furthermore, the first support member set 4020 may be positioned with an upper support member set 4022 (including the first support member 4011 and the second support member 4012) and a lower support member set 4024 (including the third support member 4013 and the fourth support member 4014). The upper support member set 4022 has a common vertical position and may engage with the upper horizontal mounting bar 3022 of the battery assembly 3000. The lower support member set 4024 has a common vertical position below the upper support member set 4022. The lower support member set 4024 may engage with the lower horizontal mounting bar 3024 of the battery assembly 3000.

[0166]

[0211] The first set of receiving members 4020 may all have a common orientation. Specifically, each receiving member is oriented with its longitudinal direction aligned with the vertical direction. This orientation ensures that the opening of each receiving member can be engaged by a horizontally oriented bar from the battery assembly.

[0167]

[0212] The second set of support members 4030 may be positioned on the vehicle 100. Specifically, the fifth support member 4015 and the sixth support member 4016 may be positioned adjacent to the first link mechanism assembly 3102, and the seventh support member 4017 and the eighth support member 4018 may be positioned adjacent to the second link mechanism assembly 3104. However, unlike the first set of support members 4020, which are positioned adjacent to the link mechanisms and inside the link mechanisms, the support members of the second set of support members 4030 are positioned adjacent to both sides outside the link mechanisms.

[0168]

[0213] The second set of receiving members 4030 may all have a common orientation. Specifically, each receiving member is oriented so that its longitudinal direction is aligned with its width direction. This orientation ensures that the opening of each receiving member can be engaged by a bar perpendicular to the battery assembly.

[0169]

[0214] Figures 51 and 52 show schematic diagrams of exemplary receiving members 4400 that may be used with this system. Specifically, Figure 51 is a schematic perspective view of the receiving member 4400 in the open position, and Figure 52 is a schematic perspective view of the receiving member 4400 in the closed position.

[0170]

[0215] The receiving member 4400 may include an outer housing 4402 and an inner locking member 4404. The inner locking member 4404 is positioned within a receiving cavity 4406 of the outer housing 4402. Furthermore, the inner locking member 4404 may be pivotable within the receiving cavity 4406.

[0171]

[0216] The outer housing 4402 includes a base portion 4420 and a raised side wall 4422 that form the boundary of the receiving cavity 4406. The side wall 4422 may be inclined toward the base portion 4420 such that the side wall 4422 is highest at the end of the receiving member 4400 and lowest in the center of the receiving member 4400. That is, the side wall 4422 may include a first notch 4424 on one side of the receiving member 4400 and a second notch 4426 on a second side of the receiving member 4400.

[0172]

[0217] The inner locking member 4404 may have an open loop or hook shape with an opening side portion 4410. When the inner locking member 4404 is rotated so that the opening side portion 4410 is positioned adjacent to the first notch 4424 and the second notch 4426, the receiving member 4400 is in the “open” position, as seen in Figure 51. In this open position, a section of the mounting bar can be positioned within the first notch 4424, the second notch 4426, and the opening side portion 4410 of the inner locking member 4404. Also in the open position, the mounting bar 4450 can be removed from the receiving member 4400.

[0173]

[0218] When the inner locking member 4404 is rotated so that the opening side 4410 is positioned within the base portion 4420, the receiving member 4400 is in the closed position as seen in Figure 52. In the closed position, a section of the mounting bar may be locked between the inner locking member 4404 and the portion of the outer housing 4402. Depending on the tension between the mounting bar and the components of the receiving member, the mounting bar may or may not be able to slide through the gap formed between the inner locking member 4404 and the base portion 4420 of the outer housing 4402.

[0174]

[0219] In some embodiments, the receiving member 4400 may be powered by hydraulic pressure. For example, in one embodiment, the receiving member 4400 may be a hydraulic latch. In other embodiments, the receiving member 4400 may be a spring load receiving member. In yet another embodiment, the receiving member 4400 may be actuated using any additional mechanical components (such as a linkage mechanism) that can be used to lock the element in place.

[0175]

[0220] In some embodiments, the receiving member may be biased to the open position. In other embodiments, the receiving member may be biased to the closed position. In yet another embodiment, the receiving member may not be biased to either the open or closed position.

[0176]

[0221] Naturally, the receiving member 4400 is merely an exemplary embodiment of the type of receiving member that can be used with the attachment / detachment system 250. In some embodiments, one or more of the receiving members in either the first set of receiving members 4220 and / or the second set of receiving members 4230 may be configured with equipment similar to that of the receiving member 4400. That is, one or more of the receiving members in this embodiment may include side walls that incline toward the center of the receiving member, as well as an internal locking member that rotates, pivots, or otherwise opens and closes around a mounting bar.

[0177]

[0222] Figures 53 and 54 show how the first set of support members 4020 engages with the upper horizontal mounting bar 3022 and the lower horizontal mounting bar 3024 when the battery assembly 3000 is lifted toward the first set of support members 4020. Specifically, as seen in Figure 53, the linkage assembly can act to lift the battery assembly 3000 toward the first set of support members 4020. As seen in Figure 54, once the upper horizontal mounting bar 3022 and the lower horizontal mounting bar 3024 are positioned within the pair of corresponding support members, the support members automatically close, securing the battery assembly 3000 in place on the vehicle 100. That is, the first support member 4111 and the second support member 4112 engage with the upper horizontal mounting bar 3022 and close around it. Specifically, the inner locking member 4080 of the first receiving member 4111 closes the area around the upper horizontal mounting bar 3022, and the inner locking member 4082 of the third receiving member 4113 closes the area around the lower horizontal mounting bar 3024. In addition, the third receiving member 4113 and the fourth receiving member 4114 (not visible in Figures 53-54) engage with the lower horizontal mounting bar 3024 and close the area around it.

[0178]

[0223] Figures 55-56 show how the second receiving member set 4030 engages with the upper horizontal mounting bar 3022 and the lower horizontal mounting bar 3024 when the battery assembly 3000 is pushed horizontally toward the second receiving member set 4030. Figures 53-54 show schematic side views of the battery assembly 3000 and the corresponding receiving member on the vehicle 100, while in contrast, Figures 55-56 show top views of the battery assembly 3000 and the corresponding receiving member.

[0179]

[0224] As shown in Figure 55, the linkage assembly can act to lift the battery assembly 3000 toward the second set of receiving members 4030. As shown in Figure 56, once the first vertical mounting bar 3072 and the second vertical mounting bar 3074 are positioned within the pair of corresponding receiving members, the receiving members automatically close to secure the battery assembly 3000 in place on the vehicle 100. Specifically, the fifth receiving member 4115 engages and closes around the second vertical mounting bar 3074, and the seventh receiving member 4117 engages and closes around the first vertical mounting bar 3072. More precisely, the inner locking member 4090 of the fifth receiving member 4115 closes around the second vertical mounting bar 3074, and the inner locking member 4092 of the seventh receiving member 4117 closes around the first vertical mounting bar 3072. Although not shown in this figure, a sixth support member 4116 may engage and close around the first vertical mounting bar 3072. Also, an eighth support member 4018 may engage and close around the second vertical mounting bar 3074.

[0180]

[0225] Figures 53–56 illustrate the process of mounting the battery assembly to the vehicle chassis by locking it into place, but it will be understood that the reverse process may be used during removal. That is, in order to remove the battery assembly, any locking mechanisms closed around the mounting bar may be opened to allow the battery assembly to be released. Once the battery assembly is released, the linkage mechanism can be activated to lower the battery assembly to the ground.

[0181]

[0226] The embodiments may include equipment for autonomously aligning the battery assembly when it is mounted in a vehicle. In some embodiments, autonomous alignment may be performed in a single direction (e.g., perpendicular alignment to the vehicle). In other embodiments, autonomous alignment may occur simultaneously in two or more directions (e.g., horizontal and vertical alignment).

[0182]

[0227] Figures 57-58 show schematic diagrams of a battery assembly aligned with respect to the vertical. Specifically, Figures 57-58 show schematic side views of several components of the vehicle 100, including when the first receiving member 4111 and the third receiving member 4113 engage with the battery assembly 3000.

[0183]

[0228] First, as seen in Figure 57, the battery assembly 3000 is misaligned with the first receiving member 4111 and the third receiving member 4113. When the upper horizontal mounting bar 3022 and the lower horizontal mounting bar 3024 come into contact with the first receiving member 4111 and the third receiving member 4113, respectively, the movement of the bars is directed downward toward the central region of the receiving member. For example, when the upper horizontal mounting bar 3022 is pressed against the inclined surface 4170 of the first receiving member 4111, the upper horizontal mounting bar 3022 may slide downward as it approaches the central region 4172 of the first receiving member 4111. Similarly, when the lower horizontal mounting bar 3024 is pressed against the inclined surface 4174 of the third receiving member 4113, the lower horizontal mounting bar 3024 may slide downward as it approaches the central region 4176 of the third receiving member 4113.

[0184]

[0229] In Figure 58, the first receiving member 4111 and the third receiving member 4113 continue until the battery assembly 3000 is properly aligned with the vertical position. At this point, the locking mechanism can close around the upper horizontal mounting bar 3022 and the lower horizontal mounting bar 3024, respectively, to secure the battery assembly 3000 to the vehicle chassis.

[0185]

[0230] Figures 57-58 illustrate the autonomous alignment process when the battery assembly 3000 has a vertical position higher than the required final alignment position, but it can be understood that a similar process occurs when the battery assembly 3000 has a vertical position lower than the final alignment position.

[0186]

[0231] Figures 59-60 show schematic diagrams of the battery assembly aligned with respect to the horizontal direction (specifically, the width direction) of the vehicle 100. Specifically, Figures 59-60 show schematic side views of several components of the vehicle 100, including the fifth receiving member 4115 and the seventh receiving member 4117 when engaging with the battery assembly 3000.

[0187]

[0232] First, as can be seen in Figure 59, the battery assembly 3000 is misaligned with the fifth support member 4115 and the seventh support member 4117. Specifically, the battery assembly 3000 is displaced horizontally by an offset 4310 in the direction perpendicular to the desired alignment boundary 4300.

[0188]

[0233] When the first vertical mounting bar 3072 and the second vertical mounting bar 3074 come into contact with the seventh receiving member 4117 and the fifth receiving member 4115, respectively, the movement of the bars is directed horizontally toward the central region of the receiving member. For example, when the second vertical mounting bar 3074 is pressed against the inclined surface 4180 of the fifth receiving member 4115, the second vertical mounting bar 3074 may slide horizontally as it approaches the central region 4182 of the fifth receiving member 4115. Similarly, when the first vertical mounting bar 3072 is pressed against the inclined surface 4184 of the seventh receiving member 4117, the first vertical mounting bar 3072 may slide horizontally as it approaches the central region 4186 of the seventh receiving member 4117.

[0189]

[0234] In Figure 60, the fifth support member 4115 and the seventh support member 4117 remain in place until the battery assembly 3000 is properly aligned with the horizontal position. At this point, the locking mechanism can secure the battery assembly 3000 to the vehicle chassis by closing around the first vertical mounting bar 3072 and the second vertical mounting bar 3074, respectively. Alternatively, in some other embodiments, the fifth support member 4115 and the seventh support member 4117 do not need to incorporate the locking mechanism.

[0190]

[0235] Figures 59 to 60 illustrate the autonomous alignment process when the battery assembly 3000 is displaced horizontally in a first direction (e.g., to the left) from the required final alignment position. It can be understood that a similar process occurs when the battery assembly 3000 is displaced horizontally in a second direction (e.g., to the right) from the final alignment position.

[0191]

[0236] As described above, the alignment of the battery assembly is performed when the horizontal and / or vertical bars of the battery assembly are pushed horizontally toward the vehicle by a linkage mechanism that raises the battery assembly and pulls it toward the receiving member assembly. Any misalignment of the battery assembly in either the vertical or horizontal direction can be autonomously corrected by the inclined side walls of the receiving member, which act to orient the vertical and horizontal positions of the battery assembly toward the proper alignment position. The proper alignment then allows the horizontal mounting bar (and / or vertical mounting bar) to be locked in place, thereby fixing the battery cage in place on the vehicle chassis.

[0192]

[0237] In different embodiments, the tolerances for vertical and horizontal positioning may vary. That is, the extent to which the battery cage can be misaligned horizontally or vertically as it approaches the mounting assembly may change. Generally, the tolerances may be determined by a variety of factors, including not only the dimensions of each mounting member but also the specific geometric shape of the side walls intended to guide the mounting bar toward a centrally aligned position.

[0193]

[0238] In some embodiments, it may be understood that one or more receiving members may be optional. In some other embodiments, for example, a second set of receiving members 4030 may be replaced by an alignment member. In contrast to receiving members which may (optionally) include equipment for locking the bar in place, the alignment member may be configured to assist in alignment only and not in locking.

[0194]

[0239] Figure 61 shows an alternative embodiment of vehicle 100 lacking a receiving member for engaging with a vertically aligned mounting bar of the battery assembly. Instead, vehicle 100 includes a set of alignment members 4502 that are mounted on the chassis of vehicle 100. The set of alignment members 4502 includes a first alignment member 4511, a second alignment member 4512, a third alignment member 4513, and a fourth alignment member 4514.

[0195]

[0240] The first alignment member 4511 includes a block of material having a V-shaped notch. This forms inclined surfaces on both sides that converge at the central position. Similar to the inclined surfaces of the receiving member described above, the inclined surfaces of the alignment member act to push the vertical mounting bar into a position centered with respect to the horizontal. The second alignment member 4512, the third alignment member 4513, and the fourth alignment member 4514 all have the same shape as the first alignment member 4511.

[0196]

[0241] Figure 61 also shows a set of support members 4560 for fixing the horizontal mounting bar. The set of support members 4560 includes a first support member 4561, a second support member 4562, a third support member 4563, and a fourth support member 4564.

[0197]

[0242] The receiving member assembly 4560 may have a slightly different design from the receiving member shown in Figures 51 and 52. The receiving member shown herein may relate to any known type of locking mechanism that can be used for the horizontal mounting bar of the battery assembly. In some cases, the receiving member assembly 4560 may include a hydraulically actuated locking mechanism.

[0198]

[0243] Using this configuration, when the receiving member aligns the battery assembly vertically, the alignment member can be used to assist in aligning the battery assembly horizontally. Furthermore, the receiving member may include a locking mechanism for securing the battery assembly in place.

[0199]

[0244] It can be seen that both the receiving member and the alignment member include convex openings. Each opening may be associated with a receiving direction. The receiving direction is related to the direction of the elongated member that can be received in the convex opening. For example, referring back to Figure 51, the receiving direction of the receiving member 4400 is the direction that extends between notches 4424 and 4426 and is parallel to the mounting bar 4450.

[0200]

[0245] As can be seen in Figure 61, the alignment members (e.g., alignment members 4511 and 4512) and the receiving members (e.g., receiving members 4561 and 4562) have non-parallel receiving directions. Specifically, the receiving directions of the alignment members and the receiving members (i.e., the orientation of the convex openings) are approximately perpendicular to each other.

[0201]

[0246] This embodiment provides a detachable system that not only positions the battery assembly in the vehicle but also integrates the battery cage with the vehicle's chassis. This is achieved by using a pre-loaded locking mechanism that grips the battery cage after it has been lifted into a specific position by the operable assembly.

[0202]

[0247] Figure 62 is a schematic diagram of one embodiment of vehicle 100 with the battery assembly 3000 mounted on the chassis 4600 of vehicle 100. Specifically, a first support member 4602 and a second support member 4604 are fixed to the chassis 4600. Furthermore, the first support member 4602 and the second support member 4604 are engaged with the upper horizontal mounting bar 3022 and the lower horizontal mounting bar 3024, respectively. Although not shown in this side view, the battery assembly 3000 may also be connected to the chassis 4600 by additional support members that engage with the horizontal mounting bars and / or by additional support members (or alignment members) that engage with the first vertical mounting bar 3072 and / or the second vertical mounting bar 3074 of the battery assembly 3000.

[0203]

[0248] By securing the battery assembly 3000 in place with a set of receiving members, the battery assembly 3000 does not need to move relative to the chassis 4600. This helps minimize any looseness in the mechanical connection between the battery assembly 3000 and the chassis 4600 of the vehicle 100, so as to achieve proper load transfer when any external force is applied.

[0204]

[0249] As an example, Figure 62 shows an exemplary scenario in which a forward impact force 4610 is applied to the front side 3009 of the battery cage 3002. Since the battery assembly 3000 is secured using a pre-loaded locking mechanism, the force may be transmitted from the battery cage 3002 to the chassis 4600 through the receiving members 4602 and 4604 without any structural obstruction occurring at the mounting point.

[0205]

[0250] While various embodiments of the present invention have been described, this description is intended to be illustrative rather than restrictive, and it will be apparent to those skilled in the art that many more embodiments and implementations are possible within the scope of the invention. Any element of any embodiment may be substituted for another element of any other embodiment, or added to another embodiment, unless specifically excluded. Therefore, the present invention should not be limited except with regard to the appended claims and their equivalents. Furthermore, various modifications and changes can be made within the scope of the appended claims.

Claims

1. A battery removal system for a battery assembly with a battery pack for an electric vehicle, The system comprises an actuated assembly including a ground link, an upper ground link, a lower ground link, and engaging components, and an actuator for moving the actuated assembly. The first end of the upper ground link is connected to the ground link at the first pivot joint, and the second end of the upper ground link is connected to the engagement component at the second pivot joint. The first end of the lower ground link is connected to the ground link at the third pivot joint, and the second end of the lower ground link is connected to the engagement component at the fourth pivot joint. The engagement component includes a first hook and a second hook, The first hook and the second hook are configured to engage with the battery assembly, The first hook has a first vertical position on the engaging component, The second hook has a second vertical position on the engaging component, The first vertical position is substantially different from the second vertical position. A battery removal system in which the actuator is pivotably connected to the upper ground link near or adjacent to the first pivot joint.

2. The battery attachment / detachment system according to claim 1, wherein the first hook is configured to engage with a first element of the battery assembly, and the second hook is configured to engage with a second element of the battery assembly, and the second element is positioned below the first element.

3. The battery attachment / detachment system according to claim 1, wherein the operable assembly is a four-bar linkage mechanism assembly, and the engaging component is a floating link.

4. The battery attachment / detachment system according to claim 3, wherein the first hook is positioned vertically below the second pivot joint.

5. The battery attachment / detachment system according to claim 4, wherein the second hook is positioned vertically below the fourth pivot joint.

6. The aforementioned four-bar linkage mechanism assembly is the first four-bar linkage mechanism assembly, The battery attachment / detachment system includes a second four-bar linkage assembly, which is another four-bar linkage assembly. The battery attachment / detachment system according to claim 3, wherein the second four-bar linkage mechanism assembly is spaced apart from the first four-bar linkage mechanism assembly.

7. The battery attachment / detachment system according to claim 1, wherein the first hook and the second hook extend forward from the engaging component so that when placed in an automobile, the first hook and the second hook are at the foremost part of the operable assembly.

8. A battery removal system, The system comprises an actuated assembly including a ground link, an upper ground link, a lower ground link, and engaging components, and an actuator for moving the actuated assembly. The first end of the upper ground link is connected to the ground link at the first pivot joint, and the second end of the upper ground link is connected to the engagement component at the second pivot joint. The first end of the lower ground link is connected to the ground link at the third pivot joint, and the second end of the lower ground link is connected to the engagement component at the fourth pivot joint. The battery attachment / detachment system includes an engagement component comprising a first hook and a second hook positioned below the first hook. It is a battery cage, An outer casing for holding the battery pack of an electric vehicle, A battery cage comprising a first retaining element and a second retaining element positioned below the first retaining element, The first hook is configured to engage with the first retaining element of the battery cage, and the second hook is configured to engage with the second retaining element of the battery cage. A battery replacement system in which the actuator is pivotably connected to the upper ground link near or adjacent to the first pivot joint.

9. The battery replacement system according to claim 8, wherein the first retaining element is a first horizontal bar, and the second retaining element is a second horizontal bar.

10. The battery replacement system according to claim 9, wherein the battery attachment / detachment system includes a second operable assembly which is another operable assembly.

11. The battery replacement system according to claim 10, wherein the battery attachment / detachment system contacts the battery cage at four contact points when the battery cage is raised or lowered by the operable assembly and the second operable assembly.

12. The battery replacement system according to claim 10, wherein the operable assembly is a four-bar linkage mechanism, and the second operable assembly is also a four-bar linkage mechanism.

13. The battery replacement system according to claim 8, wherein the battery cage is configured to hold two battery packs.

14. The battery replacement system according to claim 8, wherein the battery replacement system includes a second battery cage, the second battery cage further comprising a second outer casing for holding a second battery pack, and including a third retaining element and a fourth retaining element, the first hook configured to engage with the third retaining element, and the second hook configured to engage with the fourth retaining element.

15. The battery replacement system according to claim 8, wherein the first hook and the second hook extend forward from the engaging component so that when positioned in an automobile, the first hook and the second hook are at the foremost part of the operable assembly.

16. It is an electric vehicle, A battery cage capable of holding a battery pack for supplying power to the aforementioned electric vehicle, The system includes an onboard battery removal system for raising and lowering the battery cage, The battery attachment / detachment system further includes a four-bar linkage mechanism and an actuator for moving the four-bar linkage mechanism. The four-bar linkage mechanism includes a ground link, an upper ground link, a lower ground link, and an engaging component. The first end of the upper ground link is connected to the ground link at the first pivot joint, and the second end of the upper ground link is connected to the engagement component at the second pivot joint. The first end of the lower ground link is connected to the ground link at the third pivot joint, and the second end of the lower ground link is connected to the engagement component at the fourth pivot joint. The engagement component includes a first hook for engaging with the battery cage and a second hook positioned below the first hook, An electric vehicle in which the actuator is pivotably connected to the upper ground link near or adjacent to the first pivot joint.

17. The electric vehicle according to claim 16, wherein the engaging component is oriented substantially vertically.

18. The electric vehicle according to claim 16, wherein the four-bar linkage mechanism is operated by hydraulic pressure.

19. The four-bar linkage mechanism can be moved to a first position, and the four-bar linkage mechanism can be moved to a second position, and the second position is higher vertically than the first position. The battery cage can be attached when the four-bar linkage mechanism starts from the first position and lifts the battery cage. The electric vehicle according to claim 16, wherein the battery cage is removable when the four-bar linkage mechanism starts from the second position and lowers the battery cage.

20. The electric vehicle according to claim 16, wherein the four-bar linkage mechanism is a first four-bar linkage mechanism, and the battery attachment / detachment system includes a second four-bar linkage mechanism which is another four-bar linkage mechanism spaced apart from the first four-bar linkage mechanism.

21. The electric vehicle according to claim 16, wherein the first hook and the second hook extend forward from the engaging component so that when the electric vehicle is positioned, the first hook and the second hook become the foremost part of the four-bar linkage mechanism.

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