Apparatus and methods for tray extraction and insertion

Abstract

Apparatus (300) and methods for tray extraction and insertion are disclosed. In some implementations, an apparatus may be configured to engage a fork of a forklift (850). Once engaged with the forklift, the forklift may be used to insert and remove trays from a housing (1110). For example, the forklift may be used to extract a tray holding a plurality of batteries from a shelf (1111) of a cabinet and / or to insert such a tray into a shelf of a cabinet.

Description

APPARATUS AND METHODS FOR TRAY EXTRACTION AND INSERTIONCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of the U.S. Provisional Application No. 63 / 551 ,801 , which was filed on February 9, 2024 and is incorporated herein by reference.TECHNICAL FIELD

[0002] Aspects of the present technology relate to apparatus and methods for tray extraction and insertion. In some implementations, the apparatus and methods may be more specifically used to extract a tray holding a plurality of batteries from a shelf of a cabinet and / or to insert such a tray into a shelf of a cabinet.BACKGROUND

[0003] A rechargeable battery system may be configured to store electrical energy on a large scale within an electrical power grid. For example, electrical energy is stored during times when production (for example, from intermittent power plants, such as renewable electricity sources, such as wind power, tidal power, solar power) exceeds consumption, and is returned to tire grid when production falls below consumption. As such, the rechargeable battery system stores electrical energy when grid consumption is low and uses the stored electrical energy at times when consumption exceeds production from the power plant. Examples of such systems are disclosed in U.S. Publication No. 2018 / 0026454 Al, which is incorporated herein by reference.

[0004] In some implementations, the battery system may include a housing in which a plurality of batteries are stored. More specifically, the housing may include a plurality of shelves each of which is configured to receive a tray holding a plurality of batteries. In some implementations, a single tray may hold 28 batteries. As a result, the weight of each tray may be 1 ,500 lb. or more. To maximize space, the shelves may be vertically arranged such that the space between each of the shelves is approximately equal to the height of a battery. A battery may have a height between 5 and 10 inches (e.g., 7 inches). In other implementations, the space between each of the shelves may be approximately equal to the height of a battery plus some or all of the height of a tray. A tray may have a height between 0.5 and 3 inches.

[0005] However, when a housing is configured in this manner, it may be difficult to extract and / or insert a single tray of batteries due to the substantial weight of such a tray and the narrow space between the shelves. As a result, there is a need for apparatus and methods for extracting atray holding a plurality of batteries from a shelf of a cabinet and for inserting such a tray into a shelf of a cabinet.BRIEF SUMMARY

[0006] Improved apparatus and methods for tray extraction and insertion are disclosed. In some implementations, an apparatus may be configured to engage a fork of a forklift. Once engaged with the forklift, the forklift may be used to insert and remove trays from a housing. For example, the forklift may be used to extract a tray holding a plurality of batteries from a shelf of a cabinet and / or to insert such a tray into a shelf of a cabinet. In some implementations, the apparatus may enable the forklift to extract or insert a tray weighing between 1,500 lb. to 2,500 lb. hr some such implementations, the apparatus may also enable the forklift to extract or insert such a tray from a tight space. For example, the space may have a height tolerance of +14 inches and a width tolerance of +1.25 inches. In other words, the total amount of extra vertical space may be % inches and the total amount of extra horizontal space may be 1.25 inches (e.g., distributed as 0.75 inches on either side). In some implementations, the space may have a height of approximately 7 inches. In some implementations, the apparatus may be capable of supporting the tray when it extends 29 inches or less from an edge of a frame of the apparatus.

[0007] One aspect of the present disclosure relates to an apparatus comprising a frame configured to support a loaded tray and a drive assembly comprising a carriage and at least two pairs of rails, wherein the carriage comprises one or more components configured to slide or roll between each of the at least two pairs of rails as the carriage moves forward or backward, and wherein the carriage is configured to push the loaded tray off of the frame as it moves forward.

[0008] In some implementations, the apparatus further comprises at least two roller chains, each of which is coupled with the carriage, and at least two pairs of roller chain sprockets, each of which is coupled with a different one of the at least two roller chains, wherein rotation of the at least two pairs of roller chain sprockets causes the at least two roller chains to rotate, and wherein the rotation of the at least two roller chains causes the carriage to move forward or backward.

[0009] In some implementations, the apparatus further comprises a winch and a cable coupled to the w inch and the carriage, wherein rotation of the winch in one direction causes the carriage to move forward. In some such implementations, the cable extends through at least two pulleys.

[0010] In some implementations, the carriage is configured to engage an attachment fixture coupled to the loaded tray, wherein the carriage pushes the loaded tray when it moves forward andis engaged with the attachment fixture, and wherein the carriage pulls the loaded tray when it moves backward and is engaged with the attachment fixture. In some implementations, the carriage further comprises one or more plates configured to contact an edge of the loaded tray. In some implementations, the carriage further comprises one or more plates configured to engage the attachment fixture. In some implementations, the attachment fixture comprises a plate and one or more handles, and wherein the one or more plates extend through the one or more handles while the carriage is engaged with the attachment fixture.

[0011] In some implementations, the loaded tray weighs between 1,500 lb. and 2,500 lb. In some implementations, the loaded tray may be supported by the frame when the loaded tray extends 29 inches or less from an edge of the frame.

[0012] In some implementations, the apparatus may be part of a system that also includes the loaded tray. In some implementations, the apparatus may be part of a system that also includes a forklift. In some such implementations, the apparatus further comprises one or more members configured to engage one or more members of the forklift. In some implementations, the one or more members of the apparatus extend longitudinally in a direction parallel to the backward and forward movement of the carriage. In some implementations, tire one or more members of the apparatus extend longitudinally in a direction perpendicular to the backward and forward movement of the carriage. In some implementations, -while engaged with the apparatus, the forklift is configured to extract or insert the loaded tray from a space having a height tolerance of at least +% inches and a width tolerance of at least +1.25 inches.BRIEF DESCRIPTION OF DRAWINGS

[0013] FIG. 1 illustrates a tray and an apparatus for inserting or extracting the tray.

[0014] FIGS. 2A and 2B are perspective views of the tray of FIG. 1.

[0015] FIG. 3A is a perspective view of the apparatus of FIG. 1 .

[0016] FIG. 3B is a top-down view of the apparatus of FIG. 1.

[0017] FIG. 3C is a bottom-up view of the apparatus of FIG. 1.

[0018] FIGS. 4A and 4B are perspective views of a frame of the apparatus of FIG. 1.

[0019] FIG. 5 is a perspective view of a drive system of the apparatus of FIG. 1.

[0020] FIG. 6A is a perspective view of a carriage of the apparatus of FIG. 1 .

[0021] FIGS. 6B and 6C are perspective views of the carriage of FIG. 6 A with additional surrounding components of the apparatus of FIG. 1.

[0022] FIG. 7 is a perspective view of a pair of connection links.

[0023] FIGS. 8A-8I are photographs of a tray of batteries and an apparatus for inserting or extracting the tray from a shelf of a housing.

[0024] FIGS. 9 A and 9B are photographs of input devices of a forklift that may be used to control the apparatus of FIGS. 8A-8I.

[0025] FIG. 10 is a photograph of four trays of batteries within a housing, one of which is coupled with an attachment fixture.

[0026] FIGS. 11A-1 IH are photographs of some of the steps of a method for inserting the tray of FIGS. 8A-8I into the shelf of the housing.

[0027] FIG. 12 A is a perspective view of an apparatus for inserting or extracting a tray.

[0028] FIG. 12B is a perspective view of the apparatus of FIG. 12 A.

[0029] FIG. 12C is a top-down view of the apparatus of FIG. 12 A.

[0030] FIG. 12D is a perspective view of a frame of the apparatus of FIG. 12A.

[0031] FIG. 12E is a top-down view of a drive system of tire apparatus of FIG. 12A.

[0032] FIG. 12F is a perspective view of a carriage of the apparatus of FIG. 12 A.DETAILED DESCRIPTION

[0033] Embodiments of the present disclosure are described in detail with reference to the drawing figures wherein like reference numerals identify similar or identical elements. It is to be understood that the disclosed embodiments are merely examples of die disclosure, which may be embodied in various forms. Well-known functions or constructions are not described in detail to avoid obscuring the present disclosure in unnecessary' detail. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present disclosure in virtually any appropriately detailed structure.

[0034] FIG. 1 illustrates a system 100 drat includes a tray 200 and an apparatus 300 for inserting or extracting tray 200. As shown, apparatus 300 includes frame 400 and drive system 500. Apparatus 300 is configured to engage a fork of a forklift. While engaged, tire forklift may move apparatus 300 (and consequently tray 200 since it is resting on apparatus 300). In some embodiments, the user inputs of the forklift may be used to control drive system 500.

[0035] In some implementations, apparatus 300 may enable a forklift to extract or insert a tray weighing between 1,500 lb. to 2,500 lb. In some such implementations, these procedures may beperformed in less than 15 seconds (e.g., between 5 and 15 seconds). In some such implementations, apparatus 300 may also enable the forklift to extract or insert such a tray from a tight space. For example, the space may have a height tolerance ofinches and a width tolerance of + 1.25 inches. In other words, the total amount of extra vertical space may be % inches and the total amount of extra horizontal space may be 1.25 inches (e.g., distributed as 0.75 inches on either side). In some implementations, the space may have a height of approximately 7 inches. In some implementations, apparatus 300 may be capable of supporting the tray while it extends 29 inches or less from an edge of frame 400. For example, apparatus 300 may enable the forklift to support tray 200 while it is both supporting batteries weighing between 1,500 lb. to 2,500 lb. and while it extends 29 inches past the edge of member 411 of frame 400 (see FIGS. 4A and 4B). In some implementations, apparatus 300 may be capable of supporting the tray while it extends even farther from an edge of frame 400 (e.g. , 35 inches, 40 inches, or more).

[0036] FIGS. 2A and 2B are perspective views of tray 200. As shown tray 200 includes members 211-214, 220, and 231-236. Tray 200 is also coupled with hoist rings 241 and 242. Members 211-214 define an outer perimeter of tray 200. Vertical members 231-236 may support a plurality of batteries. Horizontal member 220 provides additional support for vertical members 231-236. In some implementations, vertical members 231-236 may be spaced such that the distance between them is less than the width of a battery. As a result, a battery may be supported by a pair of members selected from members 211-214 and 231 -236. For example, four batters may be supported by members 212 and 236. Two of those batteries may be on one side of member 220 and the other two batteries may be on the other side of member 220. An example of a similar arrangement is shown in FIGS. 11A-11H. In some implementations, tray 200 may be capable of supporting between 1 ,500 lb. to 2,500 lb. In some implementations, tray 200 may include more or less members. For example, tray 200 may include three horizontal members instead of one. In some implementations, these horizontal members may be evenly spaced apart in much the same way that vertical members 231-236 are spaced apart.

[0037] FIG. 3A is a perspective view of apparatus 300. FIG. 3B is a top-down view of apparatus 300. FIG. 3C is a bottom-up view of apparatus 300. As shown, apparatus 300 includes rollers 310, which may facilitate the pushing and pulling of tray 200 by drive system 500. Rollers 310 extend through some of the members of frame 400.

[0038] FIGS. 4A and 4B are perspective views of frame 400, which is a load supporting structure. As shown, frame 400 includes members 411-414, 420, 430, 441, and 442. Members 411- 414 define an outer perimeter of frame 400. Vertical members 420 include members 421 and 422. Drive system 500 is coupled to frame 400 through vertical members 421 and 422. As shown, the spacing between vertical members 420 is not uniform. Similarly, the spacing between horizontal members 430 is not uniform. More specifically, the distance between the horizontal members 430 that are closer to member 413 is less than the distance between the horizontal members 430 that are closer to member 411. Advantageously, this may enable a forklift to better support heavier loads. As shown, a fork of a forklift may be received by members 441 and 442. However, the fork of the forklift may not extend the entire length of members 412, 414, and / or 420.

[0039] FIG. 5 is a perspective view of drive system 500. As shown, drive system 500 includes roller chains 511 and 512, roller chain sprockets 521-524, rotary shafts 531 and 532, bearing plates 541-544, rails 551-554, and carriage 600. A motor (not shown) maybe coupled to rotary shaft 532 and configured to rotate rotary shaft 532. Since roller chain sprockets 523 and 524 are also coupled to rotary shaft 532, the rotation of rotary shaft 532 will also cause roller chain sprockets 523 and 524 to rotate. Similarly, since roller chain 511 is coupled to roller chain sprocket 523 and roller chain 512 is coupled to roller chain sprocket 524, the rotation of roller chain sprockets 523 and 524 will also cause roller chains 511 and 512 to rotate. Similarly, since roller chain 511 is also coupled to roller chain sprocket 521 and roller chain 512 is also coupled to roller chain sprocket 522, the rotation of roller chains 511 and 512 will also cause roller chain sprockets 521 and 522 to rotate. Similarly, since roller chain sprockets 521 and 522 are coupled to rotary shaft 531, the rotation of roller chain sprockets 521 and 522 will also cause rotary shaft 531 to rotate.

[0040] As shown in FIG. 5, carriage 600 is coupled to roller chains 511 and 512 (e.g. , via one or more attachment links of roller chains 511 and 512). Furthermore, carriage 600 includes pins 610 that extend between rails 551-554. As roller chains 511 and 512 rotate, carriage 600 moves forward or backward. More specifically, when roller chains 511 and 512 rotate in one direction, carriage 600 may move forward towards rotary shaft 531, and when roller chains 511 and 512 rotate in the opposite direction, carriage 600 may move backward towards rotary shaft 532. As carriage 600 moves forward or backward, pins 610 slide between rails 551 -554. For example, two pins (not shown) may slide between rails 551 and 552 and two pins may slide between rails 553 and 554 (see FIG. 6B for a zoomed in perspective). Collectively, rails 551-554 and pins 610 helpto maintain the alignment of carriage 600 as it moves forward and backward. As shown, carriage 600 may advantageously be removed from rails 551-554 for easy maintenance.

[0041] Bearing plates 541-544 and rails 551-554 may be coupled to frame 400. For example, bearing plates 541 and 543 and rails 551 and 552 may be coupled to member 421, and bearing plates 542 and 544 and rails 553 and 554 may be coupled to member 422. As shown, bearing plates 541 and 542 are rotatably coupled to rotary’ shaft 531 and provide support for rotary shaft 531. Similarly, bearing plates 543 and 544 are rotatably coupled to rotary shaft 532 and provide support for rotary shaft 532.

[0042] FIG. 6A is a perspective view of carriage 600. FIGS. 6B and 6C are perspective views of carriage 600 with some of the additional surrounding components of system 100. As shown, carriage 600 includes pins 610, hoist rings 621 and 622, plates 631, 632, 681, and 682, members 641-643 and 661-663, receptacles 651 and 652, base frame 670, and spacers 690. As shown, receptacles 651 and 652 are hollow rectangular' tubes. Receptacle 651 receives a portion of member 642 and a portion of member 662. Receptacle 652 receives a portion of member 643 and a portion of member 663. As shown, members 641-643 are solid and members 661-663 are hollow’. However, members 641-643 may be hollow’ in other implementations, and members 661-663 may be solid in other implementations. Receptacles 651 and 652 and members 661-663 are supported by upper plate 681. Upper plate 681 is spaced apart from low’er plate 682 by one or more spacers 690. In some implementations, upper plate 681 may be coupled to roller chains 511 and 512. Low’er plate 682 is supported by base frame 670. Furthermore, posts 610 extend through base frame 670.

[0043] As best seen in FIG. 6C, hoist rings 621 and 622 of carriage 600 may be used for coupling apparatus 300 to hoist rings 241 and 242. For example, connection links 710 and 720, which are illustrated in FIG. 7, may be used to connect hoist ring 621 with hoist ring 241 and to connect hoist ring 622 with hoist ring 242. However, in other implementations, other types of connectors having different shapes may be used. For example, fabric straps may be used to connect hoist rings 621 and 622 wdth hoist rings 241 and 242, respectively. As also best seen in FIG. 6C, plates 631 and 632 of carriage 600 rest against member 213 of tray 200.[00441 FIGS. 8A-8I are photographs of an apparatus for inserting or extracting a tray 810 holding batteries 11 from a shelf of a housing. As showm, tray 810 has a very similar structure to that of tray 200. However, as best seen in FIG. 1 IB, which is described in more detail below, tray 810 includes three horizontal members instead of one. These members separate the batteries withina particular column. Furthermore, the apparatus of FIGS. 8A-8I has a ver)'- similar structure to that of apparatus 300. For example, it includes frame 820 and carriage 830. Frame 820 may be compared to frame 400. Carriage 830 may be compared to carriage 600. However, as discussed below, there are some structural distinctions between carriages 600 and 830.

[0045] In some implementations, the apparatus of FIGS. 8A-8I may enable a forklift to extract or insert a tray weighing between 1,500 lb. to 2,500 lb. In some such implementations, these procedures may be performed in less than 15 seconds (e.g, between 5 and 15 seconds). In some such implementations, the apparatus may also enable the forklift to extract or insert such a tray from a tight space. For example, the space may have a height tolerance of +% inches and a width tolerance of +1.25 inches. In other words, the total amount of extra vertical space may be % inches and the total amount of extra horizontal space may be 1.25 inches (e.g., distributed as 0.75 inches on either side). In some implementations, the space may have a height of approximately 7 inches. In some implementations, the apparatus of FIGS. 8A-8I may be capable of supporting the tray while it extends 29 inches or less from an edge of frame 820. For example, as shown in FIG. 1 1C, which is described in more detail below, the apparatus may enable forklift 840 to support tray 810 while it is both supporting batteries 811 (which may' weigh between 1,500 lb. to 2,500 lb.) and while it extends 29 inches or less past the edge of frame 820. In some implementations, the apparatus of FIGS. 8A-8I may be capable of supporting the tray while it extends even farther from an edge of frame 820 (e.g., 35 inches, 40 inches, or more).

[0046] As shown in FIGS. 8A-8C, frame 820 is engaged with a forklift 840. Forklift 840 includes hydraulic lines 841 that are coupled with a hydraulic motor 850. A rotor (now shown) of motor 850 is coupled to roller chain 851. Roller chain 851 is also coupled with roller chain sprocket 852 and rotary shaft 853. As the rotor of motor 850 rotates, roller chain 851, roller chain sprocket 852, and rotary shaft 853 also rotate. Much like the rotation of rotary shaft 532 causes carriage 600 to move forward and backward, the rotation of rotary shaft 853 also causes carriage 830 to move forward and backward. Similarly, the rotation of rotary shaft 853 also causes roller chain sprocket 854 and rotary shaft 855 to rotate (vc'e FIG. 81). In some implementations, motor 850 may be replaced with one or more other types of motors (e.g. , a pneumatic motor and / or an electric motor ). In some implementations, forklift 840 may be a UniCarriers Forklift Model No. MJ1F4A45LV or another similar forklift with comparable specifications. For example, forklift 840 with a side-shift attachment may be capable of lifting 8,200 lb. 187 inches in the air with a 32-inch load center.[0047} Some of the structural distinctions between carriage 600 and carriage 830 are best seen in FIG. 8D. As shown, carriage includes members 831-834. Vertical members 831 and 832 are longer than vertical members 642 and 643. Furthermore, horizontal member 641 has been replaced with two horizontal members 833 and 834. Additionally, carriage 830 does not include any members that may be compared to member 661-663 of carriage 600. As a result, receptacles 835 and 836 are structured differently. Rather than being hollow tubes with openings on both ends, there is only one opening on each of receptables 835 and 836 that is configured to receive vertical members 831 and 832, respectively. Moreover plates 837 are shaped differently than plates 631 and 632. Rather than having an L-shape, plates 837 are flat. Furthermore, plates 837 extend farther in a vertically downward direction than plates 631 and 632.

[0048] Additional structural distinctions between carriage 600 and carnage 830 are shown in FIGS. 8E-8I. For example, unlike carriage 600, carriage 830 includes a release control 860. Release control 860 may be used to disengage carriage 830 from roller chain 870. For example, in some implementations, release control 860 may be used to disengage upper plate 885 of carriage 830 from one or more attachment links of roller chain 870. As another example, rather than including both a lower plate and a base frame, carriage 830 simply includes a lower plate 883. Further, rather than having pins that extend through a base frame, members 881 and 882 have been coupled to opposing sides of lower plate 883. However, much like carriage 600, lower plate 883 is separated from an upper plate 885 by spacers 884. As yet another example, a lubricant injection point 856 may be coupled with roller chain sprocket 854.

[0049] Although structured differently, the functionality provided by many of the components of carriage 830 may be compared to the functionality provided by components of carriage 600. For example, members 881 and 882 function in much the same way as pins 610. As shown, portions of members 881 and 882 extend between rails 822 and 823. In much the same way that rails 551 and 552 are coupled to member 421 of frame 400, rails 822 and 823 are coupled to a member 821 of frame 820. As carriage 830 moves forward and backward, members 881 and 882 slide between rails 822 and 823. Collectively, rails 822 and 823 and members 881 and 882 help to maintain the alignment of carriage 830 as it moves forward and backward. As shown, carriage 830 may advantageously be removed from rails 822 and 823 for easy maintenance.

[0050] FIGS. 9A and 9B are photographs of a lever 910 and a switch 920. Both input devices are positioned in forklift 840 and may be used to control the apparatus of FIGS. 8A-8I. In FIG.9A, switch 920 is in a first position that allows lever 910 to be used to move carriage 830 forward and backward. In FIG. 9B, switch 920 is in a second position that allows lever 910 to be used to move the apparatus of FIGS. 8A-8I right and left (from the perspective of FIG. 9B). As maybe seen in FIG. 9B, the apparatus of FIGS. 8A-8I advantageously does not interfere with the ability of forklift 840 to move a load sidervays (e.g., right or left).[00511 FIG. 10 is a photograph of four trays of batteries within a housing. Notably, tray 810 is coupled with plate 1010 and handles 1021 and 1022. These components serve a similar function to that of hoist rings 241 and 242. However, handles 1021 and 1022 are specifically configured to engage with plates 837. For example, to extract or insert tray 810, plates 837 may be lowered into the openings of handles 1021 and 1022 until the bottoms of vertical members 831 and 832 contact the tops of handles 1021 and 1022, respectively. Advantageously, this may all be done by a user from, for example, forklift 840. Additionally, by making plate 1010 long, the strength of the connection between tray 810 and carriage 830 may be improved. In other implementations, a different type of attachment fixture may be coupled with tray 810 for removably coupling it with carriage 830.

[0052] FIGS. 11A-11H are photographs of some of tire steps of a method for inserting tray 810 into shelf 1111 of housing 1 110. As shown in FIG. HA, forklift 840 is carrying tray 810, which is supporting batteries 811. As shown in FIG. I IB, tray 810 is aligned with a shelf Fi l l in a housing 1110. As shown in FIGS. 11C-11 F, tray 810 is pushed by carriage 830 onto shelf 1111 of housing 1110. As shown in FIG. 11G, carriage 830 is raised to a position in which plates 837 no longer extend through handles 1021 and 1022. As shown in FIG. 11H, forklift 840 is then able to back away from housing 1110. Those skilled in the art will appreciate that this method can simply be reversed in order to, for example, extract tray 810.

[0053] FIGS. 12A and 12B are perspective views of an apparatus 1200 for inserting or extracting a tray. FIG. 12C is a top-down view of apparatus 1200. As shown, apparatus 1200 includes frame 1210, winches 1221, 1231, and 1251, cables 1222, 1232, and 1252, pulleys 1223, 1233, and 1234, carriage 1240, attachment 1260, rails 1271, 1281, and 1282, and cover 1272. FIG. 12D is a perspective view of frame 1210. As shown, frame 1210 includes members 1211-1218. Members 1212 and 1213 are hollow and configured to engage a fork of a forklift. Unlike members 441 and 442, which are arranged parallel to the movement of carriage 600, members 1212 and 1213 are arranged perpendicularly to the movement of carriage 1240. However, bothimplementations may be modified such that the arrangements of these members are reversed. The arrangement of members 441 and 442 may, for example, enable a forklift to support a heavier load, whereas the arrangement of members 1212 and 1213 may enable the same forklift to extract or insert trays from a housing with a small amount of space directly in front of its opening.

[0054] As best seen in FIG. 12E, which is a top-down view of a drive system of apparatus 1200, winches 1221 and 1231 separately control the fotward and backward movement of a tray. For example, winch 1221 may be coupled to one end of cable 1222 and a tray may be removably coupled to the opposite end of cable 1222. Cable 1222 also extends through pulley 1223. hi this scenario, winch 1221 may be used to pull the tray onto frame 1210. As another example, one end of cable 1232 is coupled to winch 1231 and the opposite end is coupled to carriage 1240. Cable 1232 also extends through pulleys 1233 and 1234. When a tray is loaded on frame 1210, winch 1231 may be used to move carriage 1240 such that is pushes the tray off of frame 1210. Once the tension created by winch 1231 is released, a pulling force generated by a spring in winch 1251, which is coupled to carriage 1240 via cable 1252, will cause carriage 1240 to return to the position shown in FIG. 12E. However, in some implementations, winch 1251 and cable 1252 may be removed from apparatus 1200, and a user may manually move carriage 1240. In some implementations, winches 1221 and 1231 may be powered by a hand drill. In some implementations, winches 1221 and 1231 may be powered by an electric, hydraulic, and / or pneumatic motor. In some implementations, a user in a forklift may be able to remotely control such motors.

[0055] FIG. 12F is a perspective view of carriage 1240. As shown, carriage 1240 includes rollers 1241, base frame 1242, plate 1243, receptacle 1244, and member 1245. In much the same way that pins 610 slide between rails 551-554, rollers 1241 may roll between rails 1281 and 1282. Furthermore, although narrower, base frame 1242 may be compared to base frame 670. Similarly, plate 1243 may be compared to plates 681 and 682, receptacle 1244 may be compared to receptables 651 and 652, and member 1245 may be compared to vertical members 642 and 643. In some implementations, attachment 1260 may be removably coupled with member 1245. As shown, when not in use, attachment 1260 may be removably coupled with member 1212 for storage. The addition of attachment 1260 may, for example, enable apparatus 1200 to more efficiently insert or extract trays with different dimensions (e.g., shorter vertical members). In some implementations, a plate similar to any one of plates 631, 632, or 837 may be coupled tomember 1245 or attachment 1260 for engagement with a tray. In some implementations, the width of carriage 1240 may be increased in order to increase the amount of surface area of a tray that is contacted by carriage 1240.

[0056] In some implementations, apparatus 1200 may enable a forklift to extract or insert a tray weighing between 1,500 lb. to 2,500 lb. In some such implementations, these procedures may be performed in less than 15 seconds (e.g., between 5 and 15 seconds). In some such implementations, apparatus 1200 may also enable the forklift to extract or insert such a tray from a tight space. For example, the space may have a height tolerance of +H inches and a width tolerance of +1.25 inches. In other words, the total amount of extra vertical space may be H inches and the total amount of extra horizontal space may be 1.25 inches (e.g., distributed as 0.75 inches on either side). In some implementations, the space may have a height of approximately 7 inches. In some implementations, apparatus 1200 may be capable of supporting the tray while it extends 29 inches or less from an edge of frame 1210. For example, apparatus 1200 may enable the forklift to support a tray while it is both supporting batteries weighing between 1,500 lb. to 2,500 lb. and while it extends 29 inches past the edge of member 1215 of frame 1210. In some implementations, apparatus 1200 may be capable of supporting the tray while it extends even farther from an edge of frame 1210 (e.g., 35 inches, 40 inches, or more).

[0057] From the foregoing and with reference to the various figure drawings, those skilled in the art will appreciate that certain modifications may also be made to the present disclosure without departing from the scope of the same. For example, comparable components in one of the abovenoted implementations may be replaced with one another. For example, pins 610 may be replaced with rollers 1241. As another example, the dimensions of one or more components may be adjusted. For example, the length of vertical members 642, 643, 831 and / or 832 may be increased or decreased. While several embodiments of the disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be consumed as limiting, but merely as exemplifications of particular' embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.

Claims

CLAIMS1. An apparatus comprising: a frame configured to support a loaded tray; and a drive assembly comprising a carriage and at least two pairs of rails, wherein the carriage comprises one or more components configured to slide or roll between each of the at least two pairs of rails as the carriage moves forward or backward, and wherein the carriage is configured to push the loaded tray off of the frame as it moves forward.

2. The apparatus of claim 1, further comprising: at least two roller chains, each of which is coupled with the carriage; and at least two pairs of roller chain sprockets, each of which is coupled with a different one of the at least two roller chains, wherein rotation of the at least two pairs of roller chain sprockets causes the at least two roller chains to rotate, and wherein the rotation of the at least two roller chains causes the carriage to move forward or backward.

3. The apparatus of claim 1, further comprising: a winch; and a cable coupled to the winch and the carriage, wherein rotation of the winch in one direction causes the carriage to move forward.

4. The apparatus of claim 3, wherein the cable extends through at least two pulleys.

5. The apparatus of any one of claims 1-4, wherein the carriage is configured to engage an attachment fixture coupled to the loaded tray, and wherein the carriage pushes the loaded tray when it moves forward and is engaged with the attachment fixture, and wherein the carriage pulls the loaded tray when it moves backward and is engaged with the attachment fixture.

6. The apparatus of claim 5, wherein the carriage further comprises one or more plates configured to contact an edge of the loaded tray.

7. The apparatus of claim 5, wherein the carriage further comprises one or more plates configured to engage the attachment fixture.

8. The apparatus of claim 7, wherein the attachment fixture comprises a plate and one or more handles, and wherein the one or more plates extend through the one or more handles while the carriage is engaged with the attachment fixture.

9. The apparatus of any one of claims 1-8, wherein tire loaded tray weighs between 1,500 lb. and 2,500 lb.

10. The apparatus of any one of claims 1-9, wherein support for the loaded tray is provided by the frame when tire loaded tray extends 29 inches or less from an edge of the frame.I L A system comprising the apparatus of any one of claims 1-10 and the loaded tray.

12. A system comprising the apparatus of any one of claims 1-10 and a forklift, wherein the apparatus of any one of claims 1 -10 further comprises one or more members configured to engage one or more members of the forklift.

13. The system of claim 12, wherein the one or more members of the apparatus of any one of claims I -10 extend longitudinally in a direction parallel to the backward and forward movement of the carriage.

14. The system of claim 12, wherein the one or more members of the apparatus of any one of claims 1-10 extend longitudinally in a direction perpendicular to the backward and forward movement of the carriage.

15. The system of any one of claims 12-14, wherein while engaged with the apparatus of any one of claims 1-10, the forklift is configured to extract or insert the loaded tray from a space having a height tolerance of at least +% inches and a width tolerance of at least +1.25 inches.

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