Multi-bay battery charger

Abstract

A battery charger includes a first charging bay including a first charging dock configured to be physically and electrically coupled to a first battery, a second charging bay including a second charging dock configured to be physically and electrically coupled to a second battery, and a first junction box electrically coupled to and separating the first charging dock and the second charging dock. A first front side of the first charging dock is configured to couple to the first battery, a second front side of the second charging dock is configured to couple to the second battery, and the first junction box is directly coupled to a first back side of the first charging dock and a second back side of the second charging dock.

Description

MULTI-BAY BATTERY CHARGERCROSS-REFERENCE TO RELATED PATENT APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 639,482, filed on April 26, 2024, which is incorporated herein by reference in its entirety.BACKGROUND

[0002] Swappable or removable battery packs are typically recharged using a battery charger.SUMMARY

[0003] In some aspects, the present disclosure relates to a battery charger including: a first charging bay including a first charging dock configured to be physically and electrically coupled to a first battery; a second charging bay including a second charging dock configured to be physically and electrically coupled to a second battery; and a first junction box electrically coupled to and separating the first charging dock and the second charging dock, wherein a first front side of the first charging dock is configured to couple to the first battery, a second front side of the second charging dock is configured to couple to the second battery, and the first junction box is directly coupled to a first back side of the first charging dock and a second back side of the second charging dock.

[0004] In some aspects, the present disclosure relates to a battery charger stack, including: a first battery charger including a plurality of latch catches; and a second battery charger positioned on top of the first battery charger and including a plurality of latches, each latch removably coupled to one of the plurality of latch catches.

[0005] In some aspects, the present disclosure relates to a battery charger including: a DC / DC converter configured to receive DC power and adjust a voltage of the DC power; a plurality of charging docks each electrically and communicatively coupled to the DC / DC converter and configured to supply power to a battery pack; and a battery arbiter controller electrically andcommunicatively coupled to the DC / DC converter and the plurality of charging docks and configured to control the supply of power to the battery packs.

[0006] In some aspects, the present disclosure relates to a battery charger including: an AC power port configured to receive AC power; an AC to DC charger electrically coupled to the AC power port and configured to convert the AC power to DC power; a plurality of charging docks each electrically and communicatively coupled to the AC to DC charger and configured to supply power to a battery pack; and a battery arbiter controller electrically and communicatively coupled to the AC to DC charger and the plurality of charging docks and configured to control the supply of power to the battery packs.

[0007] This summary is illustrative only and is not intended to be in any way limiting. Other aspects, inventive features, and advantages of the devices or processes described herein will become apparent in the detailed description set forth herein, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a perspective view of a battery pack, according to an exemplary embodiment;

[0009] FIG. 2 is a rear perspective view of the battery pack of FIG. 1;

[0010] FIG. 3 is a perspective view of a multi-bay battery charger and battery packs, according to an exemplary embodiment;

[0011] FIG. 4 is a perspective view of a portion of the multi-bay battery charger of FIG. 3;

[0012] FIG. 5 is a front view of the multi -bay battery charger of FIG. 3;

[0013] FIG. 6 is a rear view of the multi-bay battery charger of FIG. 3;

[0014] FIG. 7A is a side view of the multi -bay battery charger of FIG. 3;

[0015] FIG. 7B is a side view of the multi-bay battery charger of FIG. 3 with legs retracted;

[0016] FIG. 7C is a side view of the multi -bay battery charger of FIG. 3 with legs retracted and a handle removed;

[0017] FIG. 8 is a top view of the multi -bay battery charger of FIG. 3;

[0018] FIG. 9 is a bottom view of the multi -bay battery charger of FIG. 3;

[0019] FIG. 10 is an angled front view of the multi -bay battery charger of FIG. 3 with the battery packs hidden;

[0020] FIG. 11 is a perspective view of a charging dock assembly of the multi-bay battery charger of FIG. 3;

[0021] FIG. 12 is a perspective view of the charging dock assembly of FIG. 11;

[0022] FIG. 13 is a perspective view of an AC power port of the multi -bay battery charger ofFIG. 3;

[0023] FIG. 14 is a perspective view of a charger of the multi-bay battery charger of FIG. 3;

[0024] FIG. 15 is a bottom view of the multi-bay battery charger of FIG. 3 without a charger;

[0025] FIG. 16 is a perspective view of a leg of the multi-bay battery charger of FIG. 3;

[0026] FIG. 17 is a side view of a stack of multi -bay battery chargers, according to an exemplary embodiment;

[0027] FIG. 18 is a perspective view of the stack of multi-bay battery chargers of FIG. 17;

[0028] FIG. 19 is a perspective view of a latch coupling together the stack of multi-bay battery chargers of FIG. 17;

[0029] FIG. 20 is a schematic illustration of the multi -bay battery charger of FIG. 3 including an external charger;

[0030] FIG. 21 is a schematic illustration of the multi-bay battery charger of FIG. 20 including a cooling system;

[0031] FIG. 22 is a schematic illustration of the multi-bay battery charger of FIG. 21 including a user interface;

[0032] FIG. 23 is a schematic illustration of the multi-bay battery charger of FIG. 3;

[0033] FIG. 24 is a schematic illustration of the multi-bay battery charger of FIG. 23 including a cooling system;

[0034] FIG. 25 is a schematic illustration of the multi -bay battery charger of FIG. 3 including a user interface; and

[0035] FIG. 26 is a schematic illustration of a battery arbiter controller connected between a plurality of battery packs and a piece of equipment.

[0036] It will be recognized that the figures are the schematic representations for purposes of illustration. The figures are provided for the purpose of illustrating one or more implementations with the explicit understanding that the figures will not be used to limit the scope of the meaning of the claims.DETAILED DESCRIPTION

[0037] Before turning to the figures, which illustrate the exemplary embodiments in detail, it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.

[0038] Referring to the figures generally, the battery pack and battery pack assemblies described herein may be used in chore products, including outdoor power equipment, standby generators, portable jobsite equipment, or other appropriate uses. Outdoor power equipment may include construction equipment, lawn mowers, riding tractors, snow throwers, pressure washers, portable generators, tillers, log splitters, zero-turn radius mowers, walk-behind mowers, wide-area walk- behind mowers, riding mowers, standing mowers, industrial vehicles such as forklifts, utility vehicles, etc. Outdoor power equipment may, for example, use an internal combustion engine to drive an implement, such as a rotary blade of a lawn mower, a pump of a pressure washer, an auger of a snow thrower, the alternator of a generator, and / or a drivetrain of the outdoor power equipment. Portable jobsite equipment includes portable light towers, mobile industrial heaters, concrete equipment (e.g., trowels, buggies, etc.), plate compactors, rammers, and portable light stands.

[0039] A “chore product” as used herein refers to any type of equipment, machine, or vehicle that may be used to perform a chore (e.g., an outdoor chore, an indoor chore, lawn care, etc.). For example, a chore product may include a motor, a pump, an actuator, a compressor, and / or another device that is electrically powered to operate some function of the chore product to facilitate performing a chore. In some embodiments, a chore is a task performed, either by a user or autonomously, at or near a household, a farm, an agricultural facility, a building, a sidewalk, a park, a parking lot, a forest, a field, and / or a lawn. In some embodiments, a chore product transports an operator and performs a chore. In some embodiments, a chore product autonomously operates to perform a chore without an operator being present on the chore product or physically / manually manipulating the chore product.Battery Pack

[0040] Referring now to FIGS. 1 and 2, a battery pack 100 is shown, according to an exemplary embodiment. The battery pack 100 may be substantially similar to the battery packs described in PCT Application No. PCT / US2023 / 033002, which is hereby incorporated by reference herein in its entirety. In some embodiments, the battery pack 100 is removable and rechargeable. Thebattery pack 100 is configured to be inserted (e.g., dropped, lowered, placed) into a receptacle integrated with a piece of power equipment, a chore product, and / or a charging station. In some embodiments, the battery pack 100 is configured to provide electrical power to a chore product or outdoor power equipment.

[0041] The battery pack 100 can be installed into a piece of equipment or chore product vertically, horizontally, and / or at any angle. In some embodiments, the battery pack 100 may be a Lithium-ion battery. However, other battery types are contemplated, such as nickel-cadmium (NiCD), lead-acid, nickel-metal hydride (NiMH), lithium polymer, etc. In some embodiments, the battery pack 100 yields a voltage of between approximately 12 and approximately 200 Volts (V) and a capacity between approximately 200 and approximately 1500 Watt-hours (Wh) of energy. In some embodiments, the battery pack 100 may have a peak discharge current of 200 Amperes (A). It is contemplated that battery assemblies of other sizes may also be used. For example, the battery pack 100 may include a capacity that is between about 1000 Wh and about 2000 Wh, or between about 1100 Wh and about 1900 Wh, or between about 1200 Wh and 1800 Wh.

[0042] The battery pack 100 includes one or more battery cell module assemblies positioned therein. The battery pack 100 may also be hot-swappable, meaning that a drained battery pack 100 can be exchanged for a new battery pack 100 without completely powering down connected equipment. As such, downtime between battery pack 100 exchanges is eliminated.

[0043] With specific reference to FIGS. 1 and 2, the battery pack 100 includes a front portion 102 and a back portion 104. In some embodiments, the front portion 102 and the back portion 104 may be coupled together (e.g., welded, fused, etc.) to create an outer housing 120 of the battery pack 100. More specifically, the outer housing 120 houses the one or more cell module assemblies. In some embodiments, the one or more cell module assemblies may be coupled to the outer housing 120 using fasteners 106 (e.g., bolts, screws, nails, etc.). In some embodiments, the outer housing 120 may be made out of an aluminum material and fabricated using an aluminum die casting process. In other embodiments, the outer housing 120 may be made out of any other type of material (e.g., metal alloys, plastic, etc.).

[0044] In some embodiments, battery pack 100 may include a user interface 108 configured to display an energy capacity or charge level of the battery pack 100 to a user. For example, the user interface may use LED lights that light up based on the energy remaining of the battery pack 100. Additionally, at least one of the LED lights may blink or flash battery fault codes. The user interface 108 can provide additional information about the battery pack 100 including condition, tool-specific data, usage data, faults, etc. For example, battery indications may include, but are not limited to, charge status, faults, battery health, battery life, battery mode, unique battery identifier, link systems, etc. In the illustrated embodiment, the user interface 108 is arranged on a top side of the outer housing 120. In some embodiments, the user interface 108 is spaced from a housing interface 125 formed between the front portion 102 and the back portion 104 of the outer housing 120. In other words, the user interface 108 is arranged so that a seal formed along the housing interface 125 does not pass around, or otherwise engage, the user interface 108, which improves the manufacturability of the outer housing 120. In some embodiments, the user interface 108 is arranged on a base wall 107 (e.g., a front or rear face that defines a larger surface area than the walls (side walls)) of the front portion 102 or the rear portion 104. Arranging the user interface 108 on the base wall 107 spaces the user interface 108 from the seal formed along the housing interface 125 does not pass around, or otherwise engage, the user interface 108. Additionally, arranging the user interface 108 on the base wall 107 enables the front portion 102 and / or the rear portion 104 to be manufactured using a die casting process with a single-cavity mold (e.g., a mold without any additional structure (core, insert, etc.) that facilitates forming an opening for the user interface 108).

[0045] In some embodiments, the battery pack 100 is configured to be removable and graspable by the handle 110. In some embodiments, the handle 110 extends from the top side of the outer housing 120. In some embodiments, the handle 110 may be overmolded with one or more handle pads 126 to reduce shock and vibration within the battery pack 100 and provide a softer feel to the handle 110. Further, overmolding the handle 110 with the handle pads 126 may provide electrical insulation. In some embodiments, the handle 110 may be fabricated from a plastic material and fastened to the outer housing 120.

[0046] In some embodiments, the outer housing 120 includes pads 112 (e.g., protectors) positioned at each of the corners of the outer housing 120. The pads 112 are configured to provide vibration damping to the outer housing 120 and generally to the battery pack 100. In some embodiments, the handle 110 extends through a cutout or recess formed in each of the pads 112 arranged at the top side of the outer housing 120 (see, e.g., FIG. 1). In some embodiments, the pads 112 are formed from a polymer material, a thermoplastic material (e.g., TPU), or a resin material. In some embodiments, the pads 112 may cover one or more drain holes that allow fluid (e.g., water, condensation, etc.) to drain out of the outer housing 120 through a tortuous path.

[0047] With specific reference to FIG. 2, the back portion 104 of the battery pack 100 includes a mating feature 114 positioned proximate the center of the rear portion 104. In some embodiments, the mating feature 114 may be configured to be coupled to a latch or dock assembly as described in more detail below. The mating feature 114 may include a mating feature opening 116 that is defined in the outer housing 120 and one or more ports / electrical receptacle 115 positioned therein. The electrical receptacle or connector 115 is electrically coupled to the one or more battery cells within the battery pack 100. The mating feature 114 is configured to supply power from one or more cell module assemblies housed in the outer housing 120 through the ports / electrical receptacle 115 and selectively connect the battery pack 100 with at least one of a piece of power equipment and / or a charging station. In some embodiments, the mating feature114 may further include a lock (e.g., latch, clip) configured to couple and decouple (e.g., lock and unlock) the battery pack 100 to a respective feature on a charging station and / or a piece of equipment. In some embodiments, the mating feature 114 may be configured to connect the battery pack 100 to a piece of power equipment, a chore product, and / or a charging station through a dock assembly.

[0048] The outer housing 120 may define a recessed guide 117 that defines a recess in the back portion 104. The recessed guide 117 extends longitudinally along the outer housing 120 from a bottom side thereof to the mating feature 114. In general, the recessed guide 117 is configured to provide a guide or alignment feature that enables a user to easily align the pack electrical receptacle115 with an electrical connector in a dock assembly. In some embodiments, the mating feature114 may further include outer surfaces 376 configured to be engaged by ejector pins of a dock assembly to bias the outer housing 120 to a position in which communication pins in electrical receptacle 115 are disconnected but power pins in the electrical receptacle 115 are connected. The battery pack 100 also includes two rails 124 (e.g., mounting rails) that are coupled to the outer housing 120 (e.g., on a back side thereof and laterally separated from one another). In some embodiments, the rails 124 may be fabricated from stamped steel. The rails 124 are configured to provide a coupling between the outer housing 120 and a dock assembly (e.g., the dock assembly 300 described below). The rails 124 of the battery pack 100 may interface with two corresponding mounting rails 324 of the dock assembly 300. For example, the battery pack 100 may be slid onto the dock assembly 300 such that the dock assembly mounting rails 324 extend into the space between the battery pack mounting rails 124 and outer housing 120.

[0049] For example, each of the rails 124 include one or more mounting apertures that are spaced longitudinally along each of the respecting rails 124 through which a fastener (e.g., a screw, a bolt, or an equivalent fastener) is received for coupling the mounting rails 124 to the battery pack 100. Each of the fasteners may extend through the latching assembly and into a respective one of the mounting apertures to couple the dock assembly to the outer housing 120.Multi-Bay Battery Charger

[0050] Referring now to FIGS. 3-19, a multi -bay battery charger 200 is shown. In the embodiment shown, the multi-bay battery charger 200 includes four charging stations 202, each arranged to receive a battery pack (e.g., the battery pack 100). As shown, the charger 200 includes three charging bays, a left charging bay 204 and a right charging bay 204 each configured to receive one battery pack 100 and a center charging bay 204 configured to receive two battery packs 100. In some embodiments, the multi -bay battery charger 200 may include one charging bay 204 for each battery. For example, the left and right sides of the center charging bay 204 may be split into two separate charging bays. Each charging station 202 includes a charging dock assembly 300 with an electrical connector 306 (shown in further detail in FIGS. 11 and 12), with electricalcontacts or pins 208 that electrically couple to the electrical contacts in the electrical receptacle 115 of the battery pack 100.

[0051] The charging bays 204 are separated by junction boxes 210 that may contain cables and other electrical and control equipment (e g., DC / DC converter, fault detection circuits, etc.) for the adjacent charging stations 202. Two charging stations 202 (including charging dock assemblies 300) are arranged back-to-back against each junction box 210, such that each junction box 210 may serve two charging stations 202 (and thereby serve two battery packs 100). The back-to-back mounting of the dock assemblies 300 (e.g., mirrored about a central plane) to or against the junction box 210 enables back-to-back installation of the battery packs 100 into the charging bays. This may reduce the space requirements and amount or wiring required compared to a multi-bay charger that includes a separate junction box for each charging station. The charger 200 has a body 218 including a base 254, two side panels 256, a rear panel 258, the charging bays 204, and the junction boxes 210. As shown in FIG. 10, which shows the multi -bay barrier charger 200 without battery packs 100 inserted, each charging bay 204 may include a top plate 260 and a bottom plate 262 coupled via a side plate 256 and a junction box 210 and / or a charging dock assembly 300, or in the case of the center charging bay 204, the top plate 260 and bottom plate 262 may be coupled via two junction boxes 210 and / or two charging dock assemblies 300.

[0052] The charger 200 includes a support system 212 coupled to the body 218 of the charger 200 including wheels 214 for transporting the charger 200 and legs 216 for supporting the charger 200 in cooperation with the wheels 214 when the charger 200 is stationary. In some embodiments, the charger 200 may not include wheels, and may instead include additional legs 216 in the positions of the wheels 214 as shown. In other embodiments, the charger 200 may include legs 216, and may instead include additional wheels 214 in the positions of the legs 216 as shown. As shown most clearly in FIG. 7A, the support system 212 supports the charger 200 such that the charging bays 204 and battery packs 100 are at an angle to a flat surface when the legs 216 and wheels 214 are on the flat surface. The angle may be, for example, at least 5 degrees, at least 10 degrees, at least 15 degrees, or at least 20 degrees. The angle may ensure that the electrical contacts in the electrical receptacle 115 of the battery pack 100 engage the electrical contacts 208 of thecharging station 202. For example, the weight of the battery pack 100 may make it easier for a user to push the battery pack into the charging bay 204 or may ensure that the battery pack 100 slides into the charging bay 204 even without any force applied by a user. The angled charging bays 204 also help protect against the battery packs 100 falling out of the charger 200. For example, if the charger 200 included a horizontal charging bay 204, and the charger 200 were positioned on an angled surface, an insufficiently engaged battery pack 100 could slide out of the charging bay 204, potentially damaging the battery or injuring a user. In some embodiments, the charging bays 204 may not be angled and may include additional features to ensure that battery packs 100 do not fall out of the charger 200.

[0053] As shown in FIGS. 7B, 7C and 16-18, the legs 216 may be repositionable in multiple positions using, for example, a spring plunger 220. The legs 216 may be rotatably coupled to the body 218 of the charger 200, for example, by one or more fasteners 222 (or pins, etc.). The spring plunger 220 includes a pin 224 biased in the direction of the legs 216 by a spring and a handle 226 that can be pulled by a user to retract the pin 224. The pin 224 may extend into a hole 228 in the leg 216 to restrict the rotation of the leg 216 about the fastener 222. The leg 216 may include multiple holes 228 so that the leg 216 can be positioned in multiple rotational positions based on the hole into which the pin 224 extends. For example, FIGS. 17 and 18 show two chargers 200 in a stacked configuration. The legs 216 of each charger may be operable in a deployed configuration, as shown in the lower charger of FIG. 17, to support the charger 200 when stationary and may be operable in a stowed position, as shown in the upper charger of FIG. 17, by rotating (retracting, etc.) the legs under the body 218 of the charger 200 such that the pin 224 extends into a different hole 228. The stowed position may be useful for transportation of a charger 200 or, as discussed above, when stacking chargers 200. As shown in the Figures, the two legs 216 are connected via a crossbar 230 (see FIGS. 16 and 18) so that the legs 216 rotate together, and the charger includes only a single spring plunger 220. In some embodiments, the charger 200 may include a spring plunger 220 on each side to restrict the rotation of each leg 216. In some embodiments, the legs 216 may not be joined by a crossbar 230 and may each have an associated spring plunger 220. As shown in FIG. 7B, with the legs retracted, the charger 200 may rest on aflat surface with the charging bays 204 substantially parallel to the surface. This configuration may allow the charger 200 to be stored, for example, on a storage rack.

[0054] The charger 200 may include a handle 232 for transporting the charger 200. To transport the charger 200, a user may use the handle 232 to tilt the charger to lift the charger off of the legs 216 so that the charger 200 is supported only by the wheels. The user may then pull the handle 232 to roll the charger 200. The handle 232 is positioned on the back side of the charger 200 so that when the charger 200 is tilted for transportation, the angle of the charging bays 204 relative to the ground increases rather than decreases. This may help ensure that the battery packs 100 do not fall out of the charging bays during transportation. The handle 232 may be removably coupled to the charger 200. For example, as shown in the Figures, the handle 232 may slide into tubes 234 on each side of the charger 200. Pins 237 may be inserted through the tubes 234 and the handle 232 to retain the handle. Removing the handle 232 may help stop users from moving the charger 200 when the charger 200 is plugged in. As discussed below, removing the handle 232 may also be useful when multiple chargers 200 are stacked. Further, as shown in FIG. 7C, with the handle 232 removed, the charger may be positioned on a surface resting on its back (e.g., on the wheels 214 and the tubes 234). In this position, the charging bays 204 may be oriented substantially perpendicular to the surface, and the battery packs 100 may be inserted and removed from above.

[0055] The charger 200 may include latches 250 (e.g., draw latches, adjustable-grip draw latches, etc.) to couple multiple chargers together, e.g., in a stacked configuration. As discussed above FIGS. 17 and 18 show two chargers 200 stacked and coupled together by latches 250. In some embodiments, each charger 200 may include three latches 250 mounted near the bottom of the charger body 218, for example, with one latch 250 on each side of the charger 200 and one latch 250 near the back of the charger 200. Each charger 200 may also include three corresponding catches 252 mounted near the top of the charger body 218. One charger 200 may be stacked on another charger 200 and the latches 250 of the upper charger 200 may be removably coupled to the catches 252 of the lower charger 200. The legs 216 of the upper charger 200 may be rotated into the stowed position and pinned in place by the spring plunger 220 such that the legs 216 of the upper charger 200 do not interfere with the battery packs 100 inserted into the lower charger200. In some embodiments, different features may be used to removably couple the stacked chargers 200, such as clevis pins or spring plungers. As shown in FIGS. 17 and 18, the handle 232 of the lower charger 200 may be removed and the handle of the upper charger 200 may be used to move both chargers 200. Alternatively, the handle 232 of the upper charger 200 could be removed and the handle 232 of the lower charger 200 may be used to move both chargers 200. Because each charger 200 may include both latches 250 and catches 252, the chargers 200 may be stacked in any order (e.g., with any charger 200 on top of any other charger 200), and more than two chargers 200 may be stacked. The top plates 260 of the outer charging bays 204 may include recesses or pockets 261 configured to receive the wheels 214 of a charger 200 stacked above the charging bays 204.

[0056] The charger 200 may be configured to be connected to an alternating current (AC) power source. As shown most clearly in FIG. 13, the charger 200 includes an AC power port 236 extending through the rear panel 258 of the body 218 that may be connected to an AC power outlet (e.g., via an extension cord). The AC power port 236 may include a cover 238 to protect the electrical contacts in the AC power port 236 when no cord is connected to the AC power port 236. An AC to DC charger 240 may be mounted to the underside of the charger 200. An AC power input port 242 of the AC to DC charger 240 may be electrically coupled to the AC power port 236, for example, by a cord (not shown) so that the AC to DC charger 240 may receive the AC power. The AC to DC charger 240 may include various electric components and controllers to convert the AC power to direct current (DC) power (e.g., a rectifier) and to supply the DC power to each of the junction boxes 210 and charging stations 202. The AC to DC charger 240 may include a DC power output port 244 that may output power (e.g., via a cord or cable) to the junction boxes 210 and charging stations 202. The AC to DC charger 240 may include a housing 246 with fins 248 for dissipating heat from the AC to DC charger 240. In some embodiments, the AC to DC charger 240 may be positioned in other locations on the charger 200, for example, on the back, on the side, or within an enclosure inside the charger 200.

[0057] In some embodiments, the charger 200 may not include an onboard AC to DC charger240. Instead, the AC to DC charger 240 may be remote from the charger 200 and coupled to thecharger 200, for example, by a cable. Thus, DC power may be supplied directly to the charger 200 rather than converting AC power to DC power onboard the charger 200. FIG. 15 shows an example embodiment of the charger 200 that does not include the AC to DC charger 240.

[0058] Each charging station 202 may include a dock assembly 300, as shown in FIGS. 11 and 12. In some embodiments, the dock assembly 300 may be substantially similar to the dock assembly 300 shown and described in PCT Application No. PCT / US2023 / 033002, which is incorporated herein by reference in its entirety. The dock assembly 300 may be coupled to the side of a charging bay 204 or to a junction box by fasteners through fastener holes 310 formed in a body 301. As discussed above, the dock assembly 300 may include mounting rails 324 configured to interface with the mounting rails 124 of the battery pack 100. For example, the battery pack 100 may be slid into the charging bay 204 with the back portion 104 against the dock assembly 300. The rails 324 of the dock assembly 300 may slide into the space between the mounting rails 124 of the battery pack and the housing 120 of the battery pack, such that the battery pack 100 is retained against the dock assembly 10 and may not be removable without sliding the battery pack 100 out of the charging bay 204 in the opposite direction it was inserted. Thus, the mounting rails 124, 324 may cooperate to “hook” the battery pack 100 into the dock assembly. The angle of the charging bays 204 discussed with respect to FIG. 7A may correspond to a longitudinal angle of the mounting rails 324.

[0059] The dock assembly 300 may also include an electrical wiring cover 302 that is configured to cover and protect electrical wires included in the dock assembly 300. The dock assembly 300 may include a lever 304 that when pivoted as a result of pulling or displacing the lever 304 may cause the battery pack 100 to slide along the lever 304 to couple with the dock assembly 300 by locking into a recess. More specifically, the battery pack 100 may couple to the electrical connector 306 with the pack electrical receptacle 115. In some embodiments, the pins of the electrical connector 306 may vary in height based on their function. For example, the electrical connector 306 includes a connector body 326 from which alignment pins 328, communication pins 330, and power pins 332 extend. In some embodiments, the alignment pins 328 include two pins arranged at laterally outward ends of the connector body 326 that extend a farthest distance fromthe connector body 326 relative to the communication pins 330 and the power pins 332. In some embodiments, the power pins 332 are arranged laterally inwardly from the alignment pins 328 but laterally outwardly relative to the communication pins 330. In other words, the communication pins 330 are arranged laterally between the power pins 332. The power pins 332 extend from a connector body 326 a further distance than the communication pins 330 but a shorter distance than the alignment pins 328. In this way, for example, as the connector 306 is disconnected from the electrical receptacle 115, the communication pins 330 can disconnect while the power pins 332 remain connected. This allows the battery management system of the battery pack 100 to disconnect power to avoid arcing as the battery pack 100 is removed from the dock assembly 300.

[0060] The lever 304 is configured to securely couple the battery pack 100 to the dock assembly 300 so that the battery pack 100 is prevented from displacing relative to the dock assembly 300. During installation of the battery pack 100 onto the dock assembly 300, a user may arrange the electrical connector 306 and / or the wiring cover 302 within the recessed guide 117 of the outer housing 120 to ensure alignment between the pack electrical receptacle 115 and the electrical connector 306. Arranging the electrical connector 306 within the recessed guide 117 brings the outer housing 120 of the battery pack 100 into engagement with the lever 304, which may be spring-biased into a locked position. Specifically, the latching portion 320 of the lever 304 engages an outer surface of the outer housing 120. The engagement with the outer surface pivots the latching portion 320 of the lever 304 in an inward direction against the spring-bias of the lever 304. The battery pack 100 is then displaced relative to the dock assembly 300 (e.g., into the charging bay 204 until the latching portion 320 aligns with a recess formed in the outer housing 120 of the battery pack 100. Because the lever 304 is spring-biased, once the latching portion 320 aligns with the recess, the latching portion 320 automatically pivots into the recess upon alignment between the two components. With the latching portion 320 arranged within and engaged with the recess, the battery pack 100 is prevented from being displaced (e.g., pulled upward or further pushed downward into our out of the charging bay 204) relative to the dock assembly 300, and the amount of displacement between the battery pack 100 and the dock assembly 300 ensures that thepack electrical receptacle 115 electrically couples to the electrical connector 306 either simultaneously with or prior to the latching portion 320 engaging with the recess.

[0061] Referring now to FIGS. 20-25, schematic views of a battery charging system 400 are shown according to various embodiments. The wiring and control architecture of the battery charging system 400 are integrated into the charger 200, as described herein. For example, FIG. 20 shows an embodiment of the charging system 400 in which the AC to DC charger 240 is external to the multi-bay battery charger 200. The AC to DC charger 240 is connected to an AC outlet 402 via a three-prong connection including an AC hot connection 404, an AC neutral connection 406, and an AC ground connection 408. The AC to DC charger 240 receives AC power via connection to the outlet 402 and converts the AC power to DC power (e.g., using a rectifier). The AC to DC charger 240 is connected to a DC / DC converter 410 via a DC+ connection 412 (e.g., a positive DC connection) and a DC- connection 414 (e.g., a negative DC connection). The AC to DC charger 240 supplies DC power to the DC / DC converter 410, which adjusts the voltage of the DC power output from the AC to DC charger 240. The DC / DC converter 410 then supplies the adjusted-voltage DC power to the charging dock assemblies 300 via additional DC+ connections 412 and DC- connections 414. The charging dock assemblies 300 supply power to the battery packs 100 via additional DC+ connections 412 and DC- connections 414. In the illustrated embodiment, each of the charging docks 300, and thereby each of the battery packs 100, are wired and connected in parallel via the DC+ connections 412 and the DC- connections 414.

[0062] The charging system 400 also includes Controller Area Network (CAN) connections 416 between the AC to DC charger 240 and the DC / DC converter 410, between the DC / DC converter 410 and the charging dock assemblies 300, and between the charging dock assemblies 300 and the battery packs 100. The CAN connections 416 may include a CAN-High line and a CAN-Low line. The DC / DC converter 410 and the charging dock assemblies 300 may also be connected to a battery arbiter controller 418 via DC+ connections 412 and DC- connections 414 and via CAN connections 416. The battery arbiter controller 418 may receive data from the charging dock assemblies 300, and the battery packs 100 connected thereto, via the CAN connections 416 and control the flow of power to the charging dock assemblies 300. For example, the batterymanagement system of one battery pack may detect that the battery pack 100 is fully charged and may send a signal to its associated charging dock assembly 300 via their CAN connection 416. The charging dock assembly 300 may forward that signal to the battery arbiter controller 418 via their CAN connection 416. Upon receiving the signal, battery arbiter controller 418 may control the flow of power such that power flows only to the other three battery packs 100 and not to the battery pack 100 that is fully charged. Alternative charging strategies may be used by the battery arbiter controller 418 as described herein.

[0063] FIG. 21 illustrates another example embodiment of the charging system 400. The charging system 400 of FIG. 21 may be substantially similar to the charging system 400 of FIG. 20 except as shown and described herein. The charging system 400 of FIG. 21 includes four fans 420 each configured to cool a battery pack 100 and a charging dock assembly 300. The fans 420 are connected to the battery arbiter controller 418 via DC+ connections 412 and DC- connections 414. The battery management system of the battery pack 100 is configured to connect to the charging dock assembly 300 via an auxiliary DC connection 422 (e.g., via an auxiliary DC pin in the electrical receptacle 115). Each charging dock assembly 300 is connected to a relay 424 via an auxiliary DC connection 422, and the DC+ connection 412 between the fan 420 and the battery arbiter controller 418 passes through the relay 424. The battery management system of the battery pack 100 may send a signal to the charging dock assembly 300 via their CAN connection 416 indicating a temperature measured in the battery pack 100. The charging dock assembly 300 may forward the signal to the battery arbiter controller 418 via their CAN connection 416. Based on the signal, the battery arbiter controller 418 may determine that the associated fan 420 should be controlled, for example, to be turned on or off or to adjust the fan speed. The battery arbiter controller 418 may send a command to the charging dock assembly 300 via their CAN connection 416, and the charging dock assembly 300 may send the command to the relay 424 via an auxiliary DC connection 422. Upon receiving the command, the relay 424 may enable the flow of power to the fan 420 via the DC+ connection 412.

[0064] FIG. 22 illustrates another example embodiment of the charging system 400. The charging system 400 of FIG. 22 may be substantially similar to the charging system 400 of FIG.21 except as shown and described herein. The charging system 400 of FIG. 22 also includes a user interface 426, which may be a component of the multi-bay battery charger 200. In other embodiments, the user interface 426 may be remote from the charger 200 and connected to the charging system 400 (e.g., to the battery arbiter controller 418) via a wired or wireless connection. For example, the user interface 426 may be a user interface of a mobile device, such as a smartphone, a laptop computer, or a tablet computer. As shown in FIG. 22, the user interface 426 is a component of the charger 200 and is connected to the battery arbiter controller 418 via a CAN connection 416. Power is supplied to the user interface 426 via DC+ connections 412 and DC- connections 414. The charger 200 may include a DC / DC converter 428 to reduce the voltage of the electrical current supplied to the user interface 426.

[0065] The user interface 426 may include a display screen 430 configured to display information about the charger 200. For example, the user interface 426 may display the state of charge and / or battery health information for each battery pack 100 connected to the charger 200 and may display information relating to faults in the charger 200 or the battery packs 100. The user interface 426 may also display expected times of charge completion for the battery packs 100 via the display screen 430. The user interface 426 may include user input features 432 (buttons, knobs, touchscreen, switches, keyboard, etc.) with which a user may provide inputs to the user interface 426, e.g., to control the operation of the charger. For example, four battery packs 100 may be inserted into respective charging stations 202 of the charger 200, and a user may require two fully charged battery packs as soon as possible. The user may use a touchscreen on the user interface 426 to enter an input instructing the battery arbiter controller 418 to control the battery packs 100 so that the charger 200 prioritizes charging of the two battery packs 100 with the highest states of charge. The battery arbiter controller 418 may receive the instruction (e.g., via the CAN connection 416) and control the flow of power such that the two battery packs 100 with the highest states of charge are charged at their maximum rates of charge, while the other two battery packs are charged with any remaining available current or not charged at all. In some embodiments, the user may enter a desired time when the battery packs 100 will be required via the user interface 426, and the battery arbiter controller 418 may control the flow of power so that the battery packs100 reach their maximum states of charge at approximately the desired time, e.g., by slowing the charging rate to extend the longevity of the battery packs 100.

[0066] FIG. 23 illustrates another example embodiment of the charging system 400. The charging system 400 of FIG. 23 may be substantially similar to the charging system 400 of FIG.20 except as shown and described herein. In the charging system 400 of FIG. 23, the AC to DC charger 240 is onboard the multi-bay battery charger 200, rather than remote from the charger 200. Thus, in the system 400 of FIG. 23, AC power is provided to an AC power port 236, which is connected to the AC to DC charger 240 via an AC hot connection 404, an AC neutral connection 406, and an AC ground connection 408. The onboard AC to DC charger 240 converts the AC power to DC power, and the rest of the system 400 of FIG. 23 functions in substantially the same way as the system 400 of FIG. 20.

[0067] FIG. 24 illustrates another example embodiment of the charging system 400. The charging system 400 of FIG. 24 may be substantially similar to the charging system 400 of FIG.21 except as shown and described herein. Specifically, the charging system 400 of FIG. 24 may be substantially the same as the charging system 400 of FIG. 21 , except that the AC to DC charger 240 is positioned onboard the multi-bay battery charger 200, rather than remote from the charger 200 (e.g., similar to the charging system 400 of FIG. 23).

[0068] FIG. 25 illustrates another example embodiment of the charging system 400. The charging system 400 of FIG. 25 may be substantially similar to the charging system 400 of FIG.22 except as shown and described herein. Specifically, the charging system 400 of FIG. 25 may be substantially the same as the charging system 400 of FIG. 22, except that the AC to DC charger 240 is positioned onboard the multi-bay battery charger 200, rather than remote from the charger 200 (e.g., similar to the charging system 400 of FIGS. 23 and 24).

[0069] In each of the embodiments of the charging system 400 shown in FIGS. 20-25, the multibay battery charger 200 includes each of the battery packs 100 connected in parallel and the battery arbiter controller 418 is configured to control the flow of power to the battery packs 100 accordingto a predefined scheduling strategy. The battery arbiter controller 418 and the predefined scheduling program are configured to prevent battery packs from cross charging. For example, wiring the battery packs in parallel brings about the possibility of a battery pack with a high state of charge charging a battery pack with a lower state of charge. The battery arbiter controller 418 and the predefined scheduling strategy ensure that power flows from the DC charger 240 to the battery packs 100, or from the battery packs 100 to an electrical load (e.g., in a discharge application where the battery packs 100 are used to provide power to equipment).

[0070] FIG. 26 shows an exemplary embodiment of the battery arbiter controller 418 connected between a plurality of the battery packs 100, which are connected in parallel, and a piece of equipment 450. In some embodiments, the equipment 450 is the DC charger 240. In some embodiments, the equipment 450 is a piece of outdoor power equipment or a chore product. In some embodiments, the equipment 450 is an equipment controller of the outdoor power equipment or the chore product. The battery arbiter controller 418 is configured to communicate with the equipment 450 and control the flow of power to and from the battery packs 100. In this way, for example, the equipment 450 is only required to communicate with a single controller, rather than individually communicate with and control the parallel power flow to and from each of the battery packs 100.

[0071] According to an exemplary embodiment, the battery arbiter controller 418 is configured to communicate with the battery packs 100 and the equipment 450 over a CAN network (e.g., using J1939 communication protocols), and the battery arbiter controller 418 is configured to assume the F3 communication node within the CAN network, which is reserved for a battery pack. With the battery arbiter controller 418 assuming the battery node within the CAN network, the battery arbiter controller 418 facilitates control of a plurality of the battery packs 100 through a single communication point, and the battery arbiter controller 418 is configured to control the flow of power to and from the battery packs 100 according to the predefined scheduling strategy. The battery arbiter controller 418 includes a processing circuit 452 having a processor 454 and memory 456. The processing circuit 452 can be communicably connected to a communications interface such that the processing circuit 452 and the various components thereof can send and receive datavia the communications interface. The processor 454 can be implemented as a general purpose processor, an application specific integrated circuit (“ASIC”), one or more field programmable gate arrays (“FPGAs”), a group of processing components, or other suitable electronic processing components.

[0072] The memory 456 (e.g., memory, memory unit, storage device, etc.) can include one or more devices (e.g., RAM, ROM, Flash memory, hard disk storage, etc.) for storing data and / or computer code for completing or facilitating the various processes, layers and modules described in the present application. The memory 456 can be or include volatile memory or non-volatile memory. The memory 456 can include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described in the present application. According to some embodiments, the memory 456 is communicably connected to the processor 454 via the processing circuit 452 and includes computer code for executing (e.g., by the processing circuit 452 and / or the processor 454) one or more processes described herein.

[0073] The memory 456 includes a scheduling module 458 that is a reprogrammable control strategy for controlling the charge and discharge of the battery packs 100 (i.e., the predefined scheduling strategy). In some embodiments, the predefined scheduling strategy is defined by a user interacting with a user interface (e.g., the user interface 426). In some embodiments, the predefined scheduling strategy is defined by a diagnostic tool communicating with the battery arbiter controller 418 over the CAN network. In general, the predefined scheduling strategy is configured to ensure that power flows either into the battery packs 100 during charging or through a load (e.g., to the equipment 450) during discharging, and prevents power flowing between the battery packs 100 due to different states of charge. In an exemplary embodiment, the battery arbiter controller 418 is in communication with a battery management system (e.g., a battery controller having a processor and memory) within each of the battery packs 100. The battery management systems each communicate various battery parameters to the battery arbiter controller 418 (e.g., state of charge, voltage, maximum allowable charge current, cell temperature, etc.). The battery arbiter controller 418 is configured to control the power flow into and from the batterypacks 100 based on these battery parameters and the predefined scheduling strategy. For example, the predefined scheduling strategy of the battery arbiter controller 418 may be programmed to charge the battery packs 100 one at a time, going from the battery pack 100 with the highest state of charge to the lowest state of charge. The predefined scheduling strategy of the battery arbiter controller 418 may be programmed to charge the battery packs 100 one at a time, going from the battery pack 100 with the lowest state of charge to the highest state of charge. The predefined scheduling strategy of the battery arbiter controller 418 may be programmed to charge one of the battery packs 100 with the lowest state of charge and then once the battery pack 100 is charged to within a predefined value of one of the battery packs 100 with the next lowest state of charge, charge the two battery packs 100 together, and so on until all of the battery packs 100 are within the predetermined value in state of charge and are being charged together.

[0074] The predefined scheduling strategy of the battery arbiter controller 418 may be programmed to discharge the battery packs 100 one at a time, going from the battery pack 100 with the highest state of charge to the lowest state of charge. The predefined scheduling strategy of the battery arbiter controller 418 may be programmed to discharge the battery packs 100 one at a time, going from the battery pack 100 with the lowest state of charge to the highest state of charge. The predefined scheduling strategy of the battery arbiter controller 418 may be programmed to discharge one of the battery packs 100 with the highest state of charge and then once the battery pack 100 is discharged to within a predefined value of one of the battery packs 100 with the next highest state of charge, discharge the two battery packs 100 together, and so on until all of the battery packs 100 are within the predetermined value in state of charge and are being discharged together. The battery arbiter controller 418 is not limited to only the charge and discharge strategies disclosed herein and may be configured to carry out various combinations of charging and discharging strategies and sequences based on state of charge or other battery parameters.

[0075] The various charge and discharge strategies defined within the scheduling module 458 of the battery arbiter controller 418 may be user-selectable and changed depending on a particular application or type of the equipment 450. And with the predefined scheduling strategy being storedon the battery arbiter controller 418, the equipment 450 communicates with the battery arbiter controller 418 as if it is communicating with a single battery pack, which simplifies the control of the various battery packs 100 connected in parallel.

[0076] As utilized herein with respect to numerical ranges, the terms “approximately,” “about,” “substantially,” and similar terms generally mean + / - 10% of the disclosed values. When the terms “approximately,” “about,” “substantially,” and similar terms are applied to a structural feature (e.g., to describe its shape, size, orientation, direction, etc.), these terms are meant to cover minor variations in structure that may result from, for example, the manufacturing or assembly process and are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the disclosure as recited in the appended claims.

[0077] It should be noted that the term “exemplary” and variations thereof, as used herein to describe various embodiments, are intended to indicate that such embodiments are possible examples, representations, or illustrations of possible embodiments (and such terms are not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

[0078] The term “coupled” and variations thereof, as used herein, means the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent or fixed) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members coupled directly to each other, with the two members coupled to each other using a separate intervening member and any additional intermediate members coupled with one another, or with the two members coupled to each other using an intervening member that is integrally formed as a single unitary body with one of the two members. If “coupled” or variations thereof are modified by an additional term (e.g., directly coupled), the generic definition of “coupled” provided above is modified by the plain language meaning of the additional term (e.g., “directly coupled” means the joining of two members without any separate intervening member), resultingin a narrower definition than the generic definition of “coupled” provided above. Such coupling may be mechanical, electrical, or fluidic.

[0079] References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below”) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.

[0080] The hardware and data processing components used to implement the various processes, operations, illustrative logics, logical blocks, modules and circuits described in connection with the embodiments disclosed herein may be implemented or performed with a general purpose single- or multi-chip processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general purpose processor may be a microprocessor, or, any conventional processor, controller, microcontroller, or state machine. A processor also may be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. In some embodiments, particular processes and methods may be performed by circuitry that is specific to a given function. The memory (e.g., memory, memory unit, storage device) may include one or more devices (e.g., RAM, ROM, Flash memory, hard disk storage) for storing data and / or computer code for completing or facilitating the various processes, layers and modules described in the present disclosure. The memory may be or include volatile memory or non-volatile memory, and may include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described in the present disclosure. According to an exemplary embodiment, the memory is communicably connected to the processor via a processing circuit and includes computer code for executing (e.g., by the processing circuit or the processor) the one or more processes described herein.

[0081] The present disclosure contemplates methods, systems and program products on any machine-readable media for accomplishing various operations. The embodiments of the present disclosure may be implemented using existing computer processors, or by a special purpose computer processor for an appropriate system, incorporated for this or another purpose, or by a hardwired system. Embodiments within the scope of the present disclosure include program products comprising machine-readable media for carrying or having machine-executable instructions or data structures stored thereon. Such machine-readable media can be any available media that can be accessed by a general purpose or special purpose computer or other machine with a processor. By way of example, such machine-readable media can comprise RAM, ROM, EPROM, EEPROM, or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to carry or store desired program code in the form of machine-executable instructions or data structures and which can be accessed by a general purpose or special purpose computer or other machine with a processor. Combinations of the above are also included within the scope of machine-readable media. Machine-executable instructions include, for example, instructions and data which cause a general purpose computer, special purpose computer, or special purpose processing machines to perform a certain function or group of functions.

[0082] Although the figures and description may illustrate a specific order of method steps, the order of such steps may differ from what is depicted and described, unless specified differently above. Also, two or more steps may be performed concurrently or with partial concurrence, unless specified differently above. Such variation may depend, for example, on the software and hardware systems chosen and on designer choice. All such variations are within the scope of the disclosure. Likewise, software implementations of the described methods could be accomplished with standard programming techniques with rule-based logic and other logic to accomplish the various connection steps, processing steps, comparison steps, and decision steps.

[0083] It is important to note that the construction and arrangement of the multi-bay battery charger 200 and the charging system 400 as shown in the various exemplary embodiments isillustrative only. Additionally, any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein.

Claims

WHAT IS CLAIMED IS:

1. A battery charger comprising: a first charging bay comprising a first charging dock configured to be physically and electrically coupled to a first battery; a second charging bay comprising a second charging dock configured to be physically and electrically coupled to a second battery; and a first junction box electrically coupled to and separating the first charging dock and the second charging dock, wherein a first front side of the first charging dock is configured to couple to the first battery, a second front side of the second charging dock is configured to couple to the second battery, and the first junction box is directly coupled to a first back side of the first charging dock and a second back side of the second charging dock.

2. The battery charger of claim 1, wherein the first back side and the second back side are opposed.

3. The battery charger of claim 1, wherein the second charging bay further comprises a third charging dock configured to be physically and electrically coupled to a third battery, the battery charger further comprising a third charging bay comprising a fourth charging dock configured to be physically and electrically coupled to a fourth battery.

4. The battery charger of claim 3, further comprising a second junction box electrically coupled to and separating the third charging dock and the fourth charging dock.

5. The battery charger of claim 4, wherein: a third front side of the third charging dock is configured to couple to the third battery; a fourth front side of the fourth charging dock is configured to couple to the fourth battery; and the second junction box is directly coupled to a third back side of the first charging dock and a fourth back side of the second charging dock.

6. The battery charger of claim 1, further comprising a charger and a battery arbiter controller in communication with the charger, the first battery, and the second battery, wherein the battery arbiter controller is configured to control charging of the first battery and the second battery according to a predefined scheduling strategy.

7. The battery charger of claim 6, wherein the first battery and the second battery are connected in parallel, and wherein the predefined scheduling strategy controls sequentially charges the first battery and the second battery starting with one of the first battery or the second battery with a highest state of charge.

8. The battery charger of claim 6, wherein the first battery and the second battery are connected in parallel, and wherein the predefined scheduling strategy controls sequentially charges the first battery and the second battery starting with one of the first battery or the second battery with a lowest state of charge.

9. The battery charger of claim 6, wherein the first battery and the second battery are connected in parallel, and wherein the predefined scheduling strategy controls initially charges the first battery and then charges the first battery and the second battery together when a state of charge of the first battery is within a predefined value of a state of charge of the second battery.

10. The battery charger of claim 6, wherein the battery arbiter controller communicates over a CAN network and occupies an F3 communication node within the CAN network.

11. The battery charger of claim 6, further comprising a user interface, wherein the predefined scheduling strategy is user-selectable via the user interface.

12. A battery charger stack, comprising: a first battery charger comprising a plurality of latch catches; and a second battery charger positioned on top of the first battery charger and comprising a plurality of latches, each latch removably coupled to one of the plurality of latch catches.

13. The battery charger stack of claim 12, wherein the first battery charger comprises a first mounting rail configured to slidably couple to a battery pack mounting rail and a support system comprising at least one leg selectively movable between a deployed position and a stowed position, wherein, when the support system supports a first battery on a flat surface and the at least one leg is in the deployed position, the first mounting rail is at an angle of at least 5 degrees to the flat surface, and wherein when the support system supports the first battery on a flat surface and the at least one leg is in the stowed position, the first mounting rail is substantially parallel to the flat surface.

14. The battery charger stack of claim 13, wherein the second battery charger comprises a leg, wherein the leg is operable in a deployed position to support the second battery charger when the second battery charger is not positioned on top of the first battery charger and in a stowed position when the second battery charger is positioned on top of the first battery charger.

15. The battery charger stack of claim 14, wherein the second battery charger comprises a wheel to support the second battery charger when the second battery charger is not positioned on top of the first battery charger and wherein a top plate of the first battery charger comprises a pocket configured to receive a portion of the wheel when the second battery charger is positioned on top of the first battery charger.

16. The battery charger stack of claim 13, wherein the second battery charger comprises a wheel to support the second battery charger when the second battery charger is not positioned on top of the first battery charger and wherein a top plate of the first battery charger comprises a pocket configured to receive a portion of the wheel when the second battery charger is positioned on top of the first battery charger.

17. A battery charger comprising: a DC / DC converter configured to receive DC power and adjust a voltage of the DC power; a plurality of charging docks each electrically and communicatively coupled to the DC / DC converter and configured to supply power to a battery pack; and a battery arbiter controller electrically and communicatively coupled to the DC / DC converter and the plurality of charging docks and configured to control the supply of power to the battery packs.

18. The battery charger of claim 17, wherein the DC / DC converter, the plurality of charging docks, and the battery arbiter controller are communicatively coupled via a CAN network.

19. The battery charger of claim 17, wherein the DC / DC converter is configured to be communicatively coupled to an AC to DC charger via a CAN network.-SO-20. The battery charger of claim 17, further comprising a fan electrically coupled to the DC / DC converter and a relay communicatively coupled to the battery arbiter controller and configured to selectively permit power to flow to the fan in response to signals from the battery arbiter controller.

21. The battery charger of claim 17, further comprising a user interface communicably coupled to the battery arbiter controller and configured to display information regarding battery packs coupled to the plurality of charging docks.

22. The battery charger of claim 17, wherein the battery arbiter controller is configured to control charging of a first battery and a second battery according to a predefined scheduling strategy.

23. The battery charger of claim 22, wherein the first battery and the second battery are connected in parallel, and wherein the predefined scheduling strategy controls sequentially charges the first battery and the second battery starting with one of the first battery or the second battery with a highest state of charge.

24. The battery charger of claim 22, wherein the first battery and the second battery are connected in parallel, and wherein the predefined scheduling strategy controls sequentially charges the first battery and the second battery starting with one of the first battery or the second battery with a lowest state of charge.

25. The battery charger of claim 22, wherein the first battery and the second battery are connected in parallel, and wherein the predefined scheduling strategy controls initially charges the first battery and then charges the first battery and the second battery together when a state of charge of the first battery is within a predefined value of a state of charge of the second battery.

26. The battery charger of claim 22, wherein the battery arbiter controller communicates over a CAN network and occupies an F3 communication node within the CAN network.

27. The battery charger of claim 22, further comprising a user interface, wherein the predefined scheduling strategy is user-selectable via the user interface.

28. A battery charger comprising: an AC power port configured to receive AC power; an AC to DC charger electrically coupled to the AC power port and configured to convert the AC power to DC power; a plurality of charging docks each electrically and communicatively coupled to the AC to DC charger and configured to supply power to a battery pack; and a battery arbiter controller electrically and communicatively coupled to the AC to DC charger and the plurality of charging docks and configured to control the supply of power to the battery packs.

29. The battery charger of claim 28, wherein the AC to DC charger, the plurality of charging docks, and the battery arbiter controller are communicatively coupled via a CAN network.

30. The battery charger of claim 28, further comprising a fan electrically coupled to the AC to DC charger and a relay communicatively coupled to the battery arbiter controller and configured to selectively permit power to flow to the fan in response to signals from the battery arbiter controller.

31. The battery charger of claim 28, further comprising a user interface communicably coupled to the battery arbiter controller and configured to display information regarding battery packs coupled to the plurality of charging docks.

32. The battery charger of claim 28, wherein the battery arbiter controller is configured to control charging of a first battery and a second battery according to a predefined scheduling strategy.

33. The battery charger of claim 32, wherein the first battery and the second battery are connected in parallel, and wherein the predefined scheduling strategy controls sequentially charges the first battery and the second battery starting with one of the first battery or the second battery with a highest state of charge.

34. The battery charger of claim 32, wherein the first battery and the second battery are connected in parallel, and wherein the predefined scheduling strategy controls sequentially charges the first battery and the second battery starting with one of the first battery or the second battery with a lowest state of charge.

35. The battery charger of claim 32, wherein the first battery and the second battery are connected in parallel, and wherein the predefined scheduling strategy controls initially charges the first battery and then charges the first battery and the second battery together when a state of charge of the first battery is within a predefined value of a state of charge of the second battery.

36. The battery charger of claim 32, wherein the battery arbiter controller communicates over a CAN network and occupies an F3 communication node within the CAN network.

37. The battery charger of claim 32, further comprising a user interface, wherein the predefined scheduling strategy is user-selectable via the user interface.

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