Optimization of facility power demands via mobile asset controller

Abstract

A sophisticated system is disclosed for coordinating numerous power demands within a facility, most importantly during peak energy demand periods, for use in facilities that have considerable power needs for HVAC systems and the like as well as other considerable power needs for periodically recharging the batteries of fork lifts, pallet jacks and other mobile assets that are vital for operation of the facility. Innovatively, the system uses the control software running in the mobile assets for planning, directing and coordinating schedules for recharging those mobile assets based off current and historic energy needs and usage data for the facility, through wireless network connections with the facilities power management system, all to help prevent or minimize penalties for excess power consumption during peak demand periods while also minimizing the need to deactivate large power draw systems, like HVAC and / or refrigeration systems.

Description

82953.00102Title: Optimization of Facility Power Demands Via Mobile Asset ControllerInventor: Kennon GuglielmoResidence: San Antonio, TexasCitizenship: United States of AmericaOptimization of Facility Power Demands Via Mobile Asset Controller Inventor: Kennon GuglielmoCROSS REFERENCE TO RELATED PRIORITY APPLICATION

[0001] This application claims the benefit of the filing date of U.S. Provisional Application Serial No. 63 / 651,689 filed on May 24, 2024, entitled “ Battery Based Systems and Methods for Coordinating Facility Power Demands," the entire disclosure of which is hereby incorporated by reference into the present disclosure.FIELD OF THE INVENTION

[0002] The present invention relates generally to systems and methods for optimizing a facility’s use of electricity, and more particularly to systems and methods for coordinating the distribution of power between a facility’s electrical charging systems for fleets of mobile electric assets as well as other facility electrical power loads, while also managing electrical power storage at the facility, most especially in a manner that minimizes penalties during peak energy demand periods.BACKGROUND OF THE INVENTION

[0003] Terms such as “peak electricity hours,” “peak demand periods” and the like are used to refer to the time of day at which electricity consumption is at its highest and electricity rates are also at their most expensive. Peak demand periods are typical on weekdays during the afternoon and early evening hours. Alternately, “of-peak hours” are when electricity demand is at its lowest and electricity prices are at their cheapest.

[0004] For grocery distribution centers and various other types of facilities, warehouses, and similar high-volume power consumers, it is financially advantageous to operate certain powerconsumption devices of the facility during off-peak hours, where possible, when power prices are at their most affordable. Additionally, in various regions and industries, high-volume power consumers are penalized for drawing more power from the grid than a certain allotted amount during peak hour periods. Additionally, these high-power consumers can be limited or capped at drawing power from the grid at a certain rate, or penalized if they draw power from the grid past their allotted rate. Accordingly, for these and various other reasons, high-volume power consumers are highly incentivized to minimize their consumption and rate of consumption of electricity during peak demand periods.

[0005] However, many high power consumers are stuck between a rock and a hard place when prioritizing which appliances or devices to provide power to at any given time during the peak demand periods. For example, many warehouses and similar facilities employ numerous powerconsuming devices at any given time. One of the largest consumers of electricity in these facilities is typically the heating, ventilation, and air conditioning (HVAC) system. As an example, grocery facilities for storing food products are often huge buildings, often 2,000,000 square feet or more, and can require one megawatt of electricity for just powering the HVAC system of the facility alone. Another big consumer of electricity in these grocery facilities are battery-powered forklifts, and specifically lithium-ion-powered forklifts and other mobile electric devices, such as battery- powered pallet jacks, which require periodic charging when they are not in use. For more perspective, such grocery facilities may employ fifty to a hundred forklifts or pallet jacks, or even more, at any one time during normal operating hours. For many facilities, electrical vehicles are used almost non-stop during a working shift and often require charging during the day.

[0006] During peak demand hours, such facilities are often unable to simultaneously recharge the battery assemblies of mobile electric devices and also run the HVAC system without beingpenalized for drawing more power from the grid than permitted by their allotted rate. Indeed, large grocery facilities often spend $1,000,000 on energy per month, half of which might be penalty fees for exceeding peak demand hour allotments. Turning off the HVAC during peak hours to allow the forklifts or pallet jacks to charge is of course undesirable, as it can lead to uncomfortable or unsafe temperatures in the warehouse. However, the other option of waiting until off-peak hours for charging of the forklifts or pallet jacks is also undesirable, as the forklift or pallet jack is then out of service during critical working hours.

[0007] Accordingly, there has been a long-felt need for systems for contemporaneously charging high-power consuming devices like forklifts or pallet jacks while also running other large power consuming systems during peak energy demand periods. Additionally, there has been a long-felt need for systems for charging high-power consuming devices economically during peak energy demand periods. Plus, there has been a long-felt need for strategic energy management to utilize off-peak energy demand periods to effectively sustain high-power consuming devices during peak energy demand periods while also enabling use of those devices whenever they are needed.BRIEF SUMMARY OF THE INVENTION

[0008] Various embodiments of this disclosure relate to a system for coordinating power demands in a facility during peak energy demand periods. In one embodiment, the system includes an HVAC system for providing environmental control to the facility and including a power management controller for controlling operation of the HVAC system. The system further includes a fleet of mobile electric devices such as forklifts or pallet jacks, that are each powered by a rechargeable battery assembly, wherein the battery assembly includes a battery operating system supervisor (“BOSS”, “BOSS control module”, “BOSS module”) that is innovatively configured tonot only control operations of the battery assembly but also to coordinate power management decisions for the larger facility. By factoring in various current and historic inputs from the facility’s power management system as well as data relative to whether the power grid of the municipality is likely to be entering or is already in a peak power period, each BOSS module is able to make and coordinate decisions for the larger facility.

[0009] For instance, when wirelessly networked with the facility’s power management system, a BOSS module of an individual mobile asset is programmed to decide when and at what level the facility should be providing recharge power to the associated battery modules and, once decided, it then directs the operator of the mobile asset accordingly and causes the facility power circuitry to provide recharge power at the decided time period. Some variations modify the facility’s power management system to make such decisions, while others are adapted to let the respective BOSS module not only make such power management decisions for the larger facility but also to execute on those decisions.

[0010] In the process, each mobile asset’s BOSS module continuously or periodically transmits data characterizing the operating conditions of its battery assembly to the power management controller and to other mobile assets over a wireless network. The facility also includes a number of battery charging units configured to recharge the battery assembly of each mobile asset when the asset is not in use. Each mobile asset’s BOSS module is further configured to communicate to the charging unit the desired rate of charge for the battery assembly. The BOSS module is further configured to determine an optimized charging rate and time for the charging unit to charge the battery assembly in a way that allows economical charging during peak energy hours without surpassing the facility’s peak energy consumption threshold, or algorithmically determining whether a battery should strategically charge before peak energy hours, if chargingcan be delayed until after peak energy hours, or if the charge rate can be altered to economically optimize the overall facility’s power consumption usage during peak and low demand times. Other embodiments of this disclosure may also include a power management controller that is configured to calculate an optimized charging rate for the battery charging unit in such a way that allows other large power loads to be operated during peak hours without surpassing the facility’s peak energy consumption threshold.

[0011] In addition to staging the times for recharging the battery assemblies of each of the mobile assets, some aspects of the invention are embodied to not only determine and cause control over when and to what extent mobile asset batteries are recharged, but to also adjust operation of the facility’s HVAC system and / or its refrigeration units in a manner that allows environmental and refrigeration temperatures to be adequately maintained while also enabling reduction of those facility loads when a number of mobile asset battery assemblies are being recharged. To achieve as much, one or more of the mobile asset’ s BOSS modules cause the facility ’ s power management controller to perform a facility environment (or, in some embodiments, refrigeration) pre-cooling operation which includes determining a pre-cooling period in which the HVAC system cools the facility environment to a pre-cool temperature which is colder than a desired facility temperature. The power management controller is configured to calculate the pre-cooling period based at least in part on a charging schedule of the battery assembly and / or the operation conditions of the battery assembly which, in some embodiments, are communicated by the BOSS control module. The power management controller is configured to deactivate operation of the HVAC system during charging of the battery assembly and reactivate operation of the HVAC system after charging of the battery assembly is complete. In some embodiments, the BOSS control module initiates theoperations of the HVAC system, such as the activation and deactivation, by communicating with the facility’s power management controller or other facility controllers.

[0012] In addition, each mobile asset’s BOSS module, through communication to the internal battery modules and other subsystems, can provide notifications of faulty conditions limiting the battery capacity or suboptimal conditions causing decreased performance or diminished lifespan. By providing this data, scheduling can be performed to improve performance through opportunistic charging to limit unnecessary cycling and maximize battery utility. Alternatively, faulty conditions requiring maintenance, both preventative and reactive, provide optimization by notification of issues with the ability to deactivate battery modules or other systems, while still maintaining over battery functionality to address the issue or take corrective actions to prevent accelerated battery degradation. Additionally, each BOSS can communicate through the back office server to decrease peak demand spikes by commanding each assembly’s battery modules to draw a lower rate of charge for longer periods when scheduling and other factors allow to prevent peak usage.

[0013] In some embodiments, the overall facility system further includes an Energy Storage Systems (“ESS”) or generators configured to provide electricity to the facility during the charging period of the battery assembly, and the control achieved through the BOSS module programming is adapted to strategically offset the power loads through use of such generators and / or the ESS units in order to avoid penalties during peak demand periods. Moreover, in addition to using dedicated ESS units, the battery assemblies of mobile assets that are not then being used can also be used, in effect, as an ESS system in order to offset excessive power loads when necessary. In some embodiments, the ESS and / or the batteries of mobile assets not being used can be activated or deactivated by a BOSS or a power management controller. For purposes of this disclosure, theterm ESS should be understood to not only refer to dedicated ESS units but also to generators or batteries of mobile assets that are not being used, or other like power storage systems.

[0014] Many other features, advantages, alternatives and variations of the present invention will be evident to those of skill in the art in light of the following more detailed descriptions, particularly when considered by a person having ordinary skill in the art with reference to the accompanying drawings and with the aid of a good understanding of the prior art.BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Fig. 1 is an overhead concept layout view of a facility utilizing the systems described in the current disclosure.

[0016] Fig. 2A is a perspective view of a battery assembly with dashed lines depicting an internal Battery Operating System Supervisor (BOSS) module 600 and internal battery modules 300, according to an embodiment of this disclosure.

[0017] Fig. 2B is a perspective view of a battery assembly with dashed lines depicting an internal BOSS module 650, according to another embodiment of this disclosure.

[0018] Fig. 3 is prior art illustrating a side view of traditional forklift assembly.

[0019] Fig. 4 illustrates a side view of a forklift including the battery assembly 10 depicted inFig. 2, according to an embodiment of this disclosure.

[0020] Fig. 5 illustrates an exploded perspective view of the battery assembly 10 depicted in Fig. 2, according to an embodiment of this disclosure.

[0021] Fig. 6A illustrates a perspective view of an individual battery module 320 of the battery assembly 10 of Fig. 2, according to an embodiment of this disclosure.

[0022] Fig. 6B illustrates an exploded perspective view of the battery module 320 of Fig. 6A, according to an embodiment of this disclosure.

[0023] Fig. 7A illustrates a perspective view of a battery cell system of the battery module 320 of Fig. 6A, according to an embodiment of this disclosure.

[0024] Fig. 7B illustrates an exploded perspective view of the battery cell system of Fig. 7A, according to an embodiment of this disclosure.

[0025] Fig. 8 is a schematic illustrating the internal workings of a BOSS module 600 of preferred embodiments, while also showing the BOSS module’s connection to the various battery modules 300a-300h of the battery assembly.

[0026] Fig. 9 is a schematic illustrating a communication and control network facilitated by a BOSS and an HVAC system of the facility, according to an embodiment of this disclosure.

[0027] Fig. 10 is a schematic illustrating a communication and control network between a facility electrical vehicle, a battery charging unit, and a power management controller, according to an embodiment of this disclosure.

[0028] Fig. 11 is a flowchart illustrating a method for coordinating power demands of a facility, according to an embodiment of this disclosure.

[0029] Fig. 12 is a flowchart illustrating a method for coordinating power demands of a facility, according to another embodiment of this disclosure.

[0030] Fig. 13 is a flowchart illustrating a method performed by a BOSS for establishing connection with a communication network, according to an embodiment of this disclosure.

[0031] Fig. 14 is a flow chart for the decision making process of BOSS module 600 for determining when and to what level recharge power should be provided for recharging battery assembly 10.

[0032] Fig. 15 is a flow chart for the decision making and notification process of BOSS module 600 for determining when fault and / or suboptimal conditions have occurred and escalating alerts to the facility power management system and / or a user accordingly.DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0033] The following descriptions relate to presently preferred embodiments and are not to be construed as describing limits to the invention, whereas the broader scope of the invention should instead be considered with reference to the claims, which may be now appended or may later be added or amended in this or related applications. Unless indicated otherwise, it is to be understood that terms used in these descriptions generally have the same meanings as those that would be understood by persons of ordinary skill in the art. It should also be understood that the terms used are generally intended to have the ordinary meanings that would be understood within the context of the related art, and they generally should not be restricted to formal or ideal definitions, conceptually encompassing equivalents, unless and only to the extent that a particular context clearly requires otherwise.

[0034] For purposes of these descriptions, a few wording simplifications should also be understood as universal, except to the extent otherwise clarified in a particular context either in the specification or in particular claims. The use of the term “or” should be understood as referring to alternatives, although it is generally used to mean “and / or” unless explicitly indicated to refer to alternatives only, or unless the alternatives are inherently mutually exclusive. When referencing values, the term “about” may be used to indicate an approximate value, generally one that could be read as being that value plus or minus half of the value. “A” or “an” and the like may mean one or more, unless clearly indicated otherwise. Such “one or more” meanings are most especially intended when references are made in conjunction with open-ended words such as “having,”“comprising” or “including.” Likewise, “another” object may mean at least a second object or more.

[0035] The following descriptions relate principally to preferred embodiments while a few alternative embodiments may also be referenced on occasion, although it should be understood that many other alternative embodiments would also fall within the scope of the invention. It should be appreciated by those of ordinary skill in the art that the techniques disclosed in these examples are thought to represent techniques that function well in the practice of various embodiments, and thus can be considered to constitute preferred modes for their practice. However, in light of the present disclosure, those of ordinary skill in the art should also appreciate that many changes can be made relative to the disclosed embodiments while still obtaining a comparable function or result without departing from the spirit and scope of the invention.

[0036] Fig. 1 illustrates an overhead concept view of a facility that employs the systems described in this disclosure. Facility 800 illustrated in Fig 1 is a typical industrial storage warehouse, equipped with a plurality of forklifts 130, a plurality of pallet jacks 230, a plurality of battery charging units 200, a facility power management controller 806, an ESS 2800, an HVAC system 802, and a plurality of other power draws 805, such as, for a non-limiting example, facility freezer systems 805a. Dashed arrows 131 and 231 are shown to represent the electrical connection between a charging unit 200 and either a pallet jack 230 or a forklift 130, both equipped with a battery module assembly 10, as discussed in more detail below. Fig. 1 illustrates different charging units for forklifts 130 and for pallet jacks 230, but in other embodiments, the same charging unit 200 can charge both forklifts 130 and pallet jacks 230, and other mobile electric devices. As discussed in more detail below, in some embodiments, ESS 2800 is configured to provideelectricity to facility 800 and / or charging units 200 during the charging period of facility’s electric devices, such as forklifts 130 and pallet jacks 230.

[0037] Fig. 2A illustrates a perspective view of a battery module assembly 10, showing a main enclosure (“housing”) 100 that includes main cover 101 and main battery enclosure 102. Housing 100 is preferably constructed of steel or another material suitable for providing strength and stability. Battery module assembly 10 has eight battery modules (“modules”) 300 arranged vertically. When installed in housing 100, each module 300 is enclosed by main cover 101 and front cover 104. A battery operation system supervisor (“BOSS”, “BOSS control module”, “BOSS module”) 600 is disposed above the modules 300 and is electrically coupled to and configured to control certain operations of the modules 300 as well as other components of assembly 10, as will be discussed in greater detail below. Additionally, BOSS 600 is configured to transfer and receive data and communicate with a mobile device, such as forklift 130 and pallet jack 230, powered by the assembly through wired connection, as will be discussed in greater detail below. Additionally, BOSS 600 is configured to, through a network, wirelessly transfer and receive data and communicate with other systems connected to the network or to the internet, as will be discussed in greater detail below. Power from the modules 300 are transmitted by the main power cable assembly 302 to a mobile device, as will be discussed in greater detail below.

[0038] As mentioned, and will be discussed in greater detail below, BOSS 600 is configured to communicate over wireless networks (such as an loT network) using the internal communication circuitry of BOSS 600. In order to communicate on the wireless networks, the communication circuitry must be able to transmit and receive signals over the networks while being disposed within an interior of assembly 10. Accordingly, cover 101 includes a BOSS window section 110 that allows for BOSS 600 to effectively communicate from an interior of assembly 10. Forexample, in some embodiments, housing 100, including cover 101, is made of metal material that is not conducive for BOSS 600 wireless communication, as the metal would largely block or interfere signals being sent and received by BOSS 600. In some embodiments window 110 is made of a plastic material that allows for signals to be transmitted and received by BOSS 600 so that the BOSS 600 can effectively communicate on the wireless networks. In other embodiments, window 110 is simply a cutout of cover 101 that exposes parts of BOSS 600 so that BOSS can effectively transmit and receive signals over the network.

[0039] Fig. 2B illustrates a perspective view of another battery assembly 50, substantially similar to assembly 10, according to an embodiment of this disclosure. Although not visible in Fig. IB, like assembly 10, assembly 50 includes a plurality of battery modules 300 for providing electrical energy through main cable 302. Those with skill in the art will understand that assembly 50 is substantially similar to assembly 10 except for the noted differences which are discussed below. Assembly 50 comprises a housing 500 (substantially similar to housing 100) including a main cover 501 (substantially similar to main cover 101), a battery enclosure 502 (substantially similar to enclosure 102), and a front cover 504 (substantially similar to cover 104). Assembly 50 further includes a BOSS 650, substantially similar to BOSS 600. However, according to some embodiments, BOSS 650 further includes an assembly display pad 307. As will be discussed in greater detail below, assembly pad 307 is configured to display certain battery assembly operation data to an operator. In some embodiments, the display pad 307 may be configured to display monetary savings that occur as a result of implementing the systems of the current discloser, which can be relayed to the operator while the system is being operated. In some embodiments, BOSS 650, 600 are configured to communicate data such as electrical or monetary savings to other systems on the facility network, wherein the data is used to generate a report either by BOSS 600,650 or another facility system. In some embodiments, BOSS 600 is further adapted estimate and send monetary savings data and optimized performance data based on data received from the battery assembly’s individual BMS units. Pad 307 also includes interfaces, such as buttons, for the operator to engage in performing certain operations associated with the battery assembly. Some embodiments may include features that allow the operator to input charging parameters, such as schedules, charging rates, or charge thresholds. Those with skill in the art will understand that this is not an exhaustive list of charging parameters.

[0040] In some embodiments, such as in assembly 10, and as will be discussed in greater detail below, touch pad 307 is coupled with BOSS 600 through a wired connection. In other embodiments, such as in assembly 50, touch pad 307 is included as part of the assembly of BOSS 650. Further, in this embodiment, assembly 50 further includes a BOSS window 510 (substantially similar to window 110) disposed on a wall of encloser 502 adjacent to BOSS 650. Like window 110, window 510 is comprised of a suitable material for allowing wireless transmissions to be sent to and from BOSS 650, such as plastic, for example, so that BOSS 650 can effectively communicate over wireless networks. The location of BOSS 650, 600 and respective window 510, 110 on housing 500, 100 can be placed within the greater forklift in a position favorable for wireless communication. For example, in some embodiments, the side of enclosure 502 on which pad 307 is disposed is directly exposed to an outside of the forklift so that touch pad 307 can be accessed from an outside of the forklift when assembly 50 is installed in the forklift. Thus, in such embodiments, BOSS 650 is also close to an external portion of the forklift and is optimally placed for wireless communication since no intervening parts of the forklift are physically blocking the internal communication circuitry of the BOSS 650 in communicating over the networks.

[0041] Fig. 3 shows a side view of a conventional Class II electric forklift 130, which is representative of a prior art lift truck design with which and in which the disclosed rechargeable battery module assembly 10 may be incorporated, embodied or used. It should be understood that the disclosed rechargeable battery module assembly 10 may also be incorporated into other classes of lift trucks, including Class I and Class III. The particular model of forklift 130 illustrated is most like a Crown RM6000 series forklift, which specifies a 48V battery that is 38.38 inches long (i.e., the lateral dimension when installed on the forklift) x 20.75 inches wide (i.e., depth from front to rear) x 31 inches in height and that meets minimum weight requirements. As a Class II forklift, forklift 130 is a mobile truck with a lifting assembly 131 for raising and lowering forks or other load supporting members 132 that are adapted to support a load 150 thereon, for the purpose of lifting, carrying or moving that load 150.

[0042] While the load supporting members 132 are conventionally designed to support the load 150 in a cantilevered fashion, extending forward of a fulcrum generally created by the front wheels 142 of the forklift 130, heavier loads present risks of tipping over the forklift 130. Hence, minimizing that risk of tipping under load is basic to safe operation of such a forklift 130 and, in line with its classification as a Class II lift truck, the full range of weight (FL, illustrated by arrow 151) of the load 150 to be carried by forklift 130 must be properly counterbalanced by a counterweight force (Fc, illustrated by arrow 121). In other words, for safe lifting and maneuvering of a load 150 without tipping, the forward tipping torque created principally by the weight (FL, illustrated by arrow 151) of that load 150 must be exceeded by the opposing torque created principally by the counterweight force 121 (Fc) of the forklift 130, particularly for loads at the heavier end of the range of manufacturer specified load capacities for forklift 130.

[0043] In the prior art, such a forklift 130 generally includes a large lead acid battery 160 as a major part of the counterweight force (Fc), and Class II forklifts are generally designed accordingly. The design of such forklifts generally incorporates structure to safely support the weight of the forklift battery 160 within a battery compartment 122 of a particular length (i.e., depth “D”), height “H”, and width "W”. It should be understood that, with respect to these dimensional characteristics shown in Figs. 3 and 4, the width dimension is perpendicular to Figs.3 and 4.

[0044] The battery compartment 122 is generally defined in part by removable or openable panels or the like that partially or completely contain and define the space for the forklift battery 160 therein. In the case of the illustrated forklift 130, for instance, battery compartment 122 is defined in part by a seat assembly 135 and a partial side panel 136. The seat assembly 135 normally sits over the top of the forklift battery 160 but has a releasable latch that allows it to be manually pivoted up and away from the forklift battery 160 to enable an operator to access the forklift battery 160 or its compartment 122. Analogously, panel 136 or other structures are provided to help enclose and define the battery compartment 122, and panel 136 may also be either removable or openable to enable more complete access to that battery compartment 122, such as for purposes of checking or replacing the forklift battery 160 therein. Forklift 130 also has positive and negative electrical conductors for removably connecting the forklift’s electrical circuitry to the corresponding terminals of the conventional forklift battery 160.

[0045] The forklift uses a fulcrum (FF, illustrated by arrow 91) which is created between the forklift’s front wheels 142 and the underlying floor 90. If the moment created by the load force (FL) of load 150 forward of that fulcrum 91 exceeds the opposite moment of the forklift counterweight (Fc), the forklift 130 will tip forward, toward load 150, resulting in a dangeroussituation. The location of the center of gravity 161 depends partly on if the forklift is loaded or unloaded. When forks 132 are raised while carrying a load 150, the center of gravity 161 naturally shifts toward the front of the forklift and upward.

[0046] Fig. 4 shows the same representative Class II electric forklift 130 as illustrated in Fig. 3 but having a preferred rechargeable battery assembly 10 according to the teachings of the present invention operatively installed in the battery compartment 122, in place of the conventional lead acid forklift battery 160 of Fig. 3. In contrast to the conventional lead-acid battery 160, rechargeable battery assembly 10 includes a plurality of separable battery modules 300 (8 in the illustrated embodiment), each of which includes numerous lightweight lithium-ion battery cells therein. Most preferably, those numerous battery cells are of the LFP type. The entire assembly 10 can hold an operable charge for around ten hours before requiring approximately 60 minutes to recharge, in contrast to the shorter usage durations and much longer charging durations that are characteristic of conventional lead acid battery 160. Also, due to their lithium-ion chemistry, each module 300 can be cycled through about six times as many charging cycles as conventional lead- acid battery 160. Fig. 4 also illustrates a battery charging source 200 (also referred to as battery power source) that, as will be described in greater detail below, is configured to be coupled with a power input of battery assembly 10 for charging battery modules 300. In some embodiments, power source 200 is a 240V or 480V power supply. Those with skill in the art will recognize that power source 200 can be rated for more or less than 480V without departing from the scope of this disclosure.

[0047] For LFP chemistries, charge rates corresponding to one hour or less charge times are often within the recommended operating limits of the cell. The longer run times of rechargeable assembly 10 compared to conventional lead-acid batteries 160 also improves workplace efficiency.For lead-acid batteries 160, large areas are allocated for recharging. After an eight-hour work shift ends, lead-acid battery 160 is removed for recharging and another charged lead-acid battery 160 is inserted. Replacing this system with rechargeable assembly 10 can save time and valuable space in the work environment. The charging system allows for simple and less burdensome recharging by plugging in an extension cord directly into the battery module assembly 10.

[0048] As those with skill in the art will recognize, lithium-ion battery assembly 10 offers many advantages over traditional lead acid battery 160. Specifically, there are advantages related to daily operations of the facilities in which the forklifts 130 are operated, such as facilities 800, which will be discussed in greater detail below. For lead acid batteries forklifts, each forklift typically has three lead acid batteries 160 associated with it: 1 in use, 1 charging, and 1 resting. Thus, at the end of an eight-hour shift, the used battery 160 gets pulled from forklift for charging, the charging battery 160 gets removed from charging and is allowed to rest, and the resting battery 160 gets installed into the forklift for use in the next shift. As previously noted, often times these facilities employ 100 forklifts and thus require a very large amount of space for merely storing and charging the 300+ batteries 160 required for operating the fleet of forklifts. Additionally, complex robotic systems are required for pulling / installing / moving the batteries 160.

[0049] Those with skill in the art will recognize that while this disclosure discusses lithium-ion batteries in forklifts, these disclosures are not limited to the use of lithium-ion batteries in forklifts, and other embodiments include the use of lithium-ion batteries in other electric vehicles, such as pallet jacks 230.

[0050] Lithium-ion battery assembly 10 offers advantages in that it can be kept in the forklift for charging, and thus only one battery assembly 10 is required per forklift, saving the facility large amounts of space and infrastructure required for the rotation of the three batteries 160 required forlead acid forklifts. However, as will be discussed in greater detail below, because there is only one lithium-ion battery assembly 10, it must be charged at a much faster rate than lead acid batteries 160 in order to maintain the productivity of the forklift within the facility. Indeed, in some cases, battery assembly 10 must be charged at a rate eight times faster than a lead acid battery. For example, a lead acid battery 160 may be allowed to charge slowly over an eight-hour charging period, since it is just one battery 160 of a three battery 160 rotation. However, in the same day, the lithium-ion battery may only have 1 hour in which it can charge to prepare for an eight-hour work shift, and thus must be charged at eight times the rate of a traditional lead acid battery in order to maintain the same levels of production. Accordingly, as will be discussed in greater detail below, disclosed herein are systems and methods for coordinating the large power demand required to charging battery 10 with other energy demands of facility 800.

[0051] Another important advantage of rechargeable assembly 10 is the lower equivalent series resistance (ESR) in LFP batteries than lead-acid batteries 160. Lead-acid batteries 160 experience decreased performance as a result of having higher ESR. Often as these batteries 160 discharge, a “voltage droop” occurs, causing sluggish operation of the forklift truck under load or acceleration. Most often, this occurs around 6 hours into a shift, requiring an additional recharge per shift, thereby reducing the life of the battery. LFP batteries provide an improvement in sustained performance during shifts while significantly reducing the risk of voltage drop.

[0052] Sized, weighted and otherwise adapted to be roughly comparable to the conventional battery 160, the height “H”, depth “D”, and width "W” of assembly 10 are substantially the same as those for the conventional forklift battery 160 intended for use with forklift 130. Hence, assembly 10 may be described as “forklift-battery-sized”. Due to its forklift-battery-sized characteristic, for the forklift 130 as illustrated, assembly 10 is able to safely fit in the same batterycompartment 122 as conventional battery 160. The preferred embodiment of rechargeable battery assembly 10 is also weighted with centrally oriented steel plates in its base, integrally secured to its lower surface, to meet the minimum (and maximum) weight requirements of batteries to be used in forklift 130, as specified by the manufacturer of forklift 130.

[0053] Hence, for use on the Class II electric forklift 130 shown in Fig. 4, lithium-ion battery assembly 10 is adapted to fit in a Crown RM6000 forklift battery compartment 122, for use as a replacement of conventional lead-acid battery 160. More specifically, for the RM6000, lithium- ion battery assembly 10 roughly fits the dimensions of 38.38 inches long (i.e., the lateral dimension when installed on the forklift) x 20.75 inches wide (i.e., depth from front to rear) x 31 inches in height and that meets minimum weight requirements, and assembly 10 has a minimum weight of 2600 pounds, preferably with a margin of fifty pounds over the manufacturer’ s specified minimum battery weight requirement.

[0054] Those of skill in the art will understand that the dimensions, fit, shape and weight for different makes and models of forklifts will dictate a range of dimensions for alternative embodiments that are intended to be used with any particular make and model of forklift. The full range of sizes for Class I & III forklift batteries are intended for alternative embodiments. The range of minimum battery weight requirements for Class I & III electric forklifts are approximately 1,500 to 4,000 lbs., which is also intended for alternative embodiments. Those with skill in the art will also understand that the dimensions, fit, shape, and weight for different electric vehicles or mobile electric devices, such as pallet jacks, will dictate a range of dimensions for alternative embodiments that are intended to be used with other electric vehicles or mobile electric devices, such as pallet jacks 230.

[0055] Although many aspects of the present invention can be appreciated with other types of rechargeable batteries, preferred embodiments use battery cells of one of the lithium-ion types. Most preferably, each module 300 of the battery assembly 10 incorporates hundreds of self- contained battery cells of the LFP (lithium iron phosphate) type. Although all lithium-ion battery types can experience thermal runaway, LFP battery cells of the preferred embodiment have a fairly high thermal runaway temperature, of 270°C, substantially higher than the runaway temperature for NCA or other LCO cells, which are the more conventional of lithium-ion battery cells, which typically have a thermal runaway temperature of around 150°C. Although the preferred embodiment uses LFP batteries, it should be understood that some aspects of the invention can be appreciated through use of other types of rechargeable lithium-ion battery cells. For example, alternative compounds for some aspects of the lithium-ion rechargeable battery assembly 10 are contemplated to include, without limitation, lithium cobalt oxide (LiCoCh), lithium manganese oxide (LiMn2O4, Li2MnO3), lithium nickel cobalt aluminum oxide (LiNiCoAlCh), and lithium nickel manganese cobalt oxide (LiNiMnCoCL).

[0056] Within each of the battery modules 300 of the preferred embodiment, a plurality of self- contained battery cells (preferably three hundred, seventy-two cells per module 300) is connected in a combination of series and parallel using a wire bonding method. The wire bonding method connects batteries using wire bonds instead of busbars. The wire bonding is achieved through ultrasonic friction welding. By interconnecting batteries with wire bonding, the wire bonds can prevent short circuits while acting as fuses. The wire bonds are made of Aluminum-Nickel alloy wire that allows for the expected current to pass through without significant overheating and allows the wire bond to break to prevent over-currents of individual cells. Additionally, Field Effect Transistors (“FETs”) or other forms of conventional fuses are placed inside battery modules. If thecurrent carrying capacity is exceeded, the fuse will open and prevent the overcurrent from also blowing out the wire bonds. Alternative embodiments of this design may connect battery cells in parallel. Additionally, alternative methods of connecting batteries could include traditional soldering and spot welding.

[0057] Fig. 5 illustrates an exploded view of a preferred complete battery assembly 10. Preferred embodiments of rechargeable assembly 10 have eight battery modules 300a - 300h installed in a main battery enclosure 102. The complete assembly 10 preferably contains two sets of four modules 300 (a first set is 300a - 300d and a second set is 300e - 300h) arranged to be vertically oriented within enclosure 102. Alternative embodiments may have a different location or different quantities of battery modules within enclosure 102. The modules 300 can be inserted and removed from the battery enclosure 102 for repair or replacement .

[0058] Shown below the main cover 101 of housing 100 are fan assemblies 105a and 105b and BOSS Module 600. Preferably, direct current (DC) brushless fans 106 are used to cool the modules 300. Fans 106 are positioned so that one fan provides cooling for one pair of modules 300. For example, the first fan 106a, shown immediately below main cover 101, is located above modules 300g, 300h. The second fan 106d, which cannot be seen in Fig. 5 but is located next to fan 106a on fan mount 105a, is located above the modules 300e, 300f, the third fan 106b above the fifth and sixth modules 300a, 300b, and the fourth fan 106c above the modules 300c, 300d. Vents 404 on the main cover 101 allow airflow into and out of the interior of the battery module assembly 10. The fan mounts 105a, 105b rest between the main cover 101 and modules 300. Those with skill in the art will understand that, according to various embodiments of this disclosure, assembly 10 can include more or less than four fans for cooling modules 300 without departing from the scope of this disclosure.

[0059] Assembly 10 includes display 307 configured to display diagnostics for the battery module assembly 10. A user can press button pad 301 to “wake” the display 307 from sleep mode. A coded push can be used for diagnostics. There is a status bar 222 that indicates the present status of the battery module assembly 10. If the fault bar 223 lights up red, this indicates that there is a fault with at least one module 300. There are five bars 224 that light up green, using light emitting diodes (LEDs) and indicate the battery charge level of module 300. The five bars 224 will show charge status in increments of approximately 20% of charge ranging from 0% to 100% based on the number of LEDs illuminated. For example, one bar indicates that the charge is very low (around 20%), and five bars indicates the battery module assembly 10 is fully charged (100%). The state of charge is determined, at least in part, on measuring the current output of each operating battery module 300a-300h using a current sensor. The overall state of charge for battery module assembly 10 reflects the average state of charge of all of the presently operating battery modules 300a-300h. Display 307 also has a fault indicator 223 which is lit when one or more battery modules 300a- 300h experiences a fault condition. One or more battery modules 300a-300h that are in a present fault condition can be shut off such that those one or more battery modules are no longer operating and do not generate power. Any battery module 300a-300h that is not presently operating is not used to determine the overall state of charge for the battery module assembly 10.

[0060] Assembly 10 has a power junction block 304 with a plurality of cables 305. Each of the cables 305 is coupled with a positive or negative terminal of one of modules 300a-300h (module 300 terminals discussed in greater detail below) and is configured to transfer electrical energy from the plurality of modules 300a-300h to the junction block 304. Specifically, the cables 305 are coupled with bus bars of the junction block, and main power cable 302 is coupled with junction block 304 and the bus bars. Thus, the junction block 304 and cables 305 are configured to transferelectrical energy of the modules 300a-300h to the main power cable 302, and the main power cable 302 is configured to be coupled with a power inlet port for forklift 130 for powering operation of the forklift. In some embodiments, modules 300a-300h are coupled with bus bars of junction block 304 by cables 305 in series, and in some embodiments, modules 3OOa-3OOh are coupled with bus bars of junction block 304 by cables 305 in parallel.

[0061] Assembly 10 further includes communication lines 303a, 303b that enable communication between BOSS 600 and each battery module 300a-300h. Specifically, each communication line 303a, 303b has a BOSS terminal end that is configured to be coupled with one of the communication connection interfaces of BOSS 600, as will be discussed in greater detail below. Each communication line 303a, 3030b also has a plurality of module terminal ends 313 each configured to be coupled with a communication port 470 of one of the modules 300a-300h. In some embodiments, each module terminal end 313 and communication port 470 are six-pin electrical connectors. However, in other embodiments, different types of connectors are used for ends 313 and ports 470, such as 8- or 10-pin, for example. As illustrated, there are two communication lines 303a, 303b, each with four terminal ends 313. Accordingly, as shown, each module terminal end 313 of line 303a is configured for connection with a communication port 470 of one of module 300a-300d. Similarly, each module terminal ends 313 of line 303b is configured for connection with a communication port 470 of one of module 300e-300h. However, those with skill in the art will understand that other embodiments of communication lines 303a, 303b are within the scope of this disclosure. For example, there may be more or less than two communication lines 303, which can each have more or less than module terminal ends 313, depending on the number of communication lines and the number of battery modules 300.

[0062] As will be discussed in greater detail below, communication line 303a, 303b is configured to enable communication between BOSS 600 and a battery management system (“BMS”) of each battery module 300a-300h. For example, in some embodiments, each BMS can send operating, charging, or discharging data of the corresponding battery module 300a-300h to BOSS 600. In some embodiments, BOSS 600 can send operating, charging, or discharging operation commands to each module 300a-300h BMS.

[0063] Battery assembly 10 is designed to be interchangeable and replaceable with various electric vehicles, such as forklifts 130 or pallet jacks 230. That is to say, for example, battery assembly 10 can be removed from one forklift 130, for any of a number of reasons such as maintenance, repair, charging, cleaning, etc., and put back into the same or another forklift 130 for operation of the forklift 130. Accordingly, battery assembly 10, and all of the components therein, can be described as an interchangeable, replaceable, or portable battery assembly 10, as battery assembly 10 is replaceable or portable relative to the forklift 130 or pallet jack 230.

[0064] Fig. 6A illustrates a perspective view of module 300, which can be any one of modules 300a-300h. As previously discussed, on a top surface of each module 300 are communication connector port 470, a positive bus terminal 311 and a negative bus terminal 310 which are mounted and accessible. Port 470 is configured to be connected with one of the terminal ends 313 to enable communication between the module and the BOSS, and terminals 311, 310 are each configured to be connected with one of the power cables 305 to enable transfer of electrical energy between module 300 and junction block 304. A protective enclosure base 320, a cover 321, and an endcap 323 are coupled together to enclose module 300 and seal an interior of module 300 from the outside. Enclosure base 320 is preferably constructed of aluminum to dissipate heat generated by battery cells 710, and a cover 321 is preferably constructed of plastic.

[0065] Fig. 6B illustrates an exploded view of the battery module 300 subassembly. Module 300 comprises a cell array 322, which is protected by enclosure base 320 and cover 321. Endcap 323 is fastened to the cell array 322 with four screws 420. Enclosure base 320 and cover 321 are positioned with locater tabs 330 along the top edges to fit inside the endcap 323. An adhesive 728 is applied as required to inner edges of the enclosure base 320. In preferred embodiments, the adhesive is an acrylic adhesive, but the use of other types of adhesives or sealants is contemplated. A sealant 727 is applied as required to enclosure base 320, cover 321 and the endcap 323 for the purpose of sealing the interface between cover 321, endcap 323, and enclosure base 320. In preferred embodiments, the sealant may be a silicone-based sealant, but use of other sealants with similar properties is included within the scope of this disclosure.

[0066] Fig. 7A illustrates a perspective view of the battery module 300 without the cover 321, enclosure base 320, or endcap 323. As illustrated, each battery module 300 includes a printed circuit board assembly (“PCBA”) 722, which includes two printed circuit board (“PCB”) collector plates 35 la, 351b, and a battery management system (“BMS”) 700. Although the illustrated PCBA 722 includes three separate pieces, one with skill in the art will understand that, in some embodiments, PCBA 722 is a single piece that includes a collector plate and a BMS.

[0067] Fig. 7B illustrates an exploded view of the battery module components shown in Fig. 7A. Each battery cell 710 is wire bonded to PCBA 722. Located between battery cells 710 and PCBA 722 is a top plastic battery tray 720a. Positioned below the battery cell array 322 is a bottom plastic battery tray 720b. Plastic battery trays 720a, 720b are placed directly on top of and below the battery cells 710. Module 300 mounting pieces 450 are secured to a top end of cell array 322 by screws 460.

[0068] Terminals 310, 311 are electrically coupled with PCBA 722 and are thus electrically coupled with the battery cells 710, since each battery cell is electrically coupled to PCBA 722 by wire bonding, as previously discussed. Accordingly, by this electrical communication between the terminals 310, 311, and the cells 710, electrical energy of the cells 710 can be transferred to the terminals 310, 311 during operating or discharging operations, for example, and electrical power can be transferred from the terminals 310, 311 to the cells 710 during charging operations, for example. BMS 700 is configured to control certain charging, discharging, and operating operations of the cells 710. Further, BMS 700 is configured to gather data related to the cells 710, such as, for example, voltage / current levels, charge levels, status of charge, percentage of charge, temperature of cells, and other various operational data related to cells 710. BMS 700 is electrically coupled with connector port 470, and is thus able to directly communicate with BOSS 600. For example, as will be discussed in greater detail below, BMS 700 can send BOSS 600 operational data of cells 710 for BOSS 600 to use in making supervisory control determinations. Additionally, BOSS 600 can communicate with BMS 700, such as to provide charging or discharging commands to the BMS 700, for example.

[0069] Fig. 8 illustrates an internal view of BOSS 600 and its connection to battery modules 300. The top casing of BOSS 600 is made of a material that allows for transmission of cellular, satellite, Bluetooth, Wi-Fi, and other wireless signals to and from the internal antennas of BOSS 600, which will be discussed in greater detail below. BOSS 600 includes a printed circuit board (“PCB”) 602. Disposed on PCB 602 is a microprocessor 604 for controlling certain operations of assembly 10. Microprocessor 604 is disposed within a radio frequency (“RF”) shield 606 configured to protect microprocessor 604 from interference caused by cellular, satellite, Bluetooth, and Wi-Fi signals sent and received by the communication antennas 608-616, discussed in detailbelow. Microprocessor 604 is depicted in Fig. 8 in dashed line to show that the microprocessor 604 is enclosed within RF shield 606. RF shield 606 is made of a material that blocks cellular and satellite signals from microprocessor 604, such as metal, for example. Although one microprocessor 604 is described in this embodiment, those with skill in the art will understand that BOSS 600 can include one or more processors without departing from the scope of this disclosure.

[0070] Cellular antennas 608, 610 and satellite antenna 612 are also disposed on PCB 602. Antennas 608-612 are configured to communicate through different networks to allow for data transfer between BOSS 600 and other devices in communication with the networks. For example, in some embodiments, BOSS 600 is configured to communicate with other devices within an loT network or wireless communication network. For example, BOSS 600 is configured to communicate with charging unit 200 via an loT network, or in other embodiments, configured to communicate with ESS 2800 via an loT network. Cellular antenna 608 and 610 are configured to communicate in tandem through a singular modem with cellular networks determined by 2 different SIM cards, to access different cellular networks, soldered internally to the BOSS 600, although those with skill in the art will understand that alternative methods can be utilized to connect to cellular networks without departing from the scope of this disclosure. In the preferred embodiment, SIM card 1 connects to Verizon, and SIM card 2 is configured to allow access and roaming to a plethora of differing networks to allow network connectivity in areas with cellular network coverage. In addition, satellite antenna 612 is configured to communicate on a satellite network through a satellite network module that contains its own SIM-comparable data. In some embodiments, the first and second cellular networks are able to transfer information to the internet and thus enable connection for the loT network. As previously mentioned, at least an outer top casing of BOSS 600 is made of a plastic or other material that allows for antennas 608-612 to sendand receive data on their respective networks. Each antenna 608-612 is electrically coupled with processor 604 to allow for communication between the antennas 608-612 by PCB 602. Although there are three antennas 608-612 described in this embodiment, those with skill in the art will understand that BOSS 600 can include more or less than three communication antennas without departing from the scope of this disclosure. As will be discussed in greater detail below when discussing Fig. 13, microprocessor 604 is configured to perform a determination sequence to determine which of the three communication networks is desirable for communicating with another device also in communication with the three networks, or for communicating with the internet.

[0071] Wi-Fi antennas 614 and Bluetooth antenna 616 are also disposed on PCB 602. Antennas 614, 616 are configured to allow for data transfer between BOSS 600 and other devices in a certain facility. For example, in some embodiments, BOSS 600 is configured to communicate with other devices within an loT network, such as, for example, charging unit 200 and / or ESS 2800. As will be discussed in greater detail below, Wi-Fi antenna 614 is configured to connect to a Wi-Fi network of a facility and allow BOSS 600 to communicate with other devices connected to Wi-Fi network. As will be discussed in greater detail below, Bluetooth antenna 616 is configured to connect with other Bluetooth compatible devices in a facility and allow BOSS 600 to communicate with other devices via Bluetooth connection 822, which can also be referred to herein as an loT network or wireless network.

[0072] Further coupled to PCB 602 are electrical connector interfaces 614-632. According to some embodiments, electrical connector interfaces 614-632 are matching types of connector interfaces, and in some embodiments, some of electrical interfaces 614-632 are different from each other. Each interface 614-632 can be any type of electrical connector interface that can be matedwith a corresponding connector type to allow for communication between numerous devices. For example, in some embodiments, some or all of the interfaces 614 - 632 can be a male or female six-pin connector. In other embodiments, some or all of the interfaces 614 - 632 can be male or female pin connectors utilizing more or less than 6 pins. Additionally, although some types of connector interfaces have been described, those with skill in the art will recognize that interfaces 614 - 632 can comprise any type of electrical connection interface that allows for data transmission. Further, although eight interfaces 614-632 are depicted, according to various embodiments, BOSS 600 has more or less than eight such electrical interfaces.

[0073] Through PCB 602, each interface 614 - 632 is electrically coupled with the microprocessor 604, and is thus configured to transfer data received at the interface 614 - 632 from a device or component of assembly 10 electrically coupled with interface 614 - 632, as will be discussed in greater detail below. Similarly, microprocessor 604 is configured to send data transmissions and commands to each of the assembly 10 components coupled with interfaces 614 - 632. Said another way, components of assembly 10 are configured to communicate with microprocessor 604 by being coupled to one of interfaces 614 - 632.

[0074] As shown, the BOSS terminal end of each module communication line 303a, 303b (discussed in Fig. 5) is coupled with interfaces 618 and 620, respectively, and the communication line module ends 313 are connected to one of the battery modules 3OOa-3OOh by port 470. These connections allow for communication between BOSS 600 and BMS 700 of each battery module 300a-300h. Accordingly, each BMS 700 can transmit data related to its respective cells 710 to BOSS 600, such as, for example, voltage / current levels, charge levels, status of charge, percentage of charge, temperature of cells, and other various operational data related to cells 710. Similarly,BOSS 600 can send data and commands to the BMS 700 of each module 300a-300h.

[0075] Although some embodiments may only include four modules 3OOa-3OOd or 300e-300h being coupled through one interface 620 or 622, those with skill in the art will recognize that various other embodiments fall within the scope of this disclosure. For example, in some embodiments, the modules 300a-300h are each coupled with a different interface. That is to say, in some embodiments, BOSS 600 has at least eight electrical interfaces (much the same as 620 and 622), and each electrical interface is only coupled with one of modules 300a-300h. Those with skill in the art will understand that various other embodiments fall within the scope of this disclosure.

[0076] In some embodiments, fans 106a-106d, discussed in Fig. 5, are also electrically coupled withBOSS 600 through connections 614 and 616. As shown inFig. 5, fans 106b, 106c are disposed above modules 300a-300d (a first pair of fans). As shown in Fig. 5, fans 106a, 106d are disposed above modules 300e-300h (a second pair of fans). BOSS 600 is configured to provide independent control of the two pairs of fans 106a, 106d and 106b, 106c. In some embodiments, fans 106a-106d are coupled with BOSS 600 via electrical interfaces substantially the same as interfaces 620, 622. However, those with skill in the art will recognize that fans 106a-106d can be coupled with BOSS 600 using different connections points as well as by any traditional communication coupling means, such as a different type of wired junction with the BOSS 600 or by wireless connection.

[0077] Those with skill in the art will understand how independent control of each pair of fans is desirable for a number of different reasons. For example, based on cell 710 temperature data received by BOSS 600 from each of the BMSs 700, the processor 604 may determine that some of the modules 300a-300h are overheating and need to be cooled. For example, based on the temperature data received, processor 604 may determine that some or all of modules 300a-300d are overheating. Because the first pair of fans 106b, 106c are disposed directly above modules300a-300d, the first pair of fans are configured to cool modules 300a-300d. Because processor 604 determined that modules 300a-300d are overheating, and that modules 300e-300h meet satisfactory temperature requirements, the processor 604 can selectively activate the first pair of fans 106b, 106c to cool the modules 300a-300d. Accordingly, energy can be saved by only activating fans of the assembly 10 needed, rather than unnecessarily activating all fans of the assembly and wasting energy of the assembly to power the unneeded fans.

[0078] BOSS 600 can also be connected with a controller area network (CAN) of the forklift 130 or pallet jack 230. By this connection, BOSS 600 can transfer data related to the modules 300a-300h to other controllers of forklift 130 or pallet jack 230. Further, BOSS 600 can receive current or desired operating conditions of various components of forklift 130 or pallet jack 230 (such as the lift assembly or the drivetrain, for example) through the connection to CAN and control operation of assembly 10 accordingly.

[0079] Fig. 9 illustrates a communication and control schematic for a facility 800 for communication between BOSS 600 of forklift 130 / pallet jack 230 and an HVAC system 802 of the facility 800, according to an embodiment of this disclosure. Facility 800 can be a warehouse or a similar facility in which a forklift 130, pallet jack 230, multiple forklifts 130, and / or multiple pallet jacks 230 are used. As previously discussed, according to some embodiments, facility 800 is a grocery warehouse for storing food products. In some embodiments, the grocery warehouse 800 is a 2,000,000 square foot facility and employs a forklift fleet of up to 100 or more forklifts 130 operating at any given time. In these embodiments, one megawatt or more is required for operating HVAC system 802. In these embodiments, an additional one megawatt or more is required for simultaneously charging the battery assemblies 10 of the entire forklift fleet. Thus, although Fig. 9 illustrates one BOSS 600 in communication with power management controller806, those with skill in the art will recognize that, according to various embodiments, facility 800 may incorporate 50 - 100 or more forklifts 130 each with a BOSS 600 in communication with controller 806, and / or 50 - 100 or more pallet jacks 230 each with a BOSS 600 in communication with controller 806, according to the systems and methods discussed herein.

[0080] In one embodiment, HVAC system 802 includes an HVAC unit 804 and a power management controller 806 for controlling operation of HVAC unit 804. Those with skill in the art will understand that HVAC unit 804 comprises various components necessary for providing heating and cooling environmental climate control to facility 800, such as, for example, evaporator coils, condenser coils and cooling fans, blower, furnace, and duct work, and is powered by connection to an electrical power grid providing electricity to facility 800 and / or alternative power sources such as an ESS 2800. According to various embodiments, facility 800 includes multiple HVAC units 804 each independently controllable by controller 806 or a network of controllers for providing independent climate control to different zones or rooms of the facility 800. Controller 806 is electrically coupled to receive temperature reading from an interior thermometer 808 configured to gather temperature readings inside of facility 800 and an exterior thermometer 810 configured to gather temperature readings from an open outdoor exterior of facility 800. As will be discussed in greater detail below, controller 806 is configured to control operation of HVAC unit 804 based at least partially on reading from thermometers 808, 810 and thus can be referred herein as a thermostat. As those with skill in the art will understand, facility 800 can include a plurality of interior and exterior thermometers 808, 810. Finally, facility 800 includes the battery module charging unit 200 configured to charge battery modules 300a-h. Charging unit 200 is connected to the power grid providing electricity to facility 800 and uses electricity from the gridfor charging battery modules 300a-h. In some embodiments, charging unit 200 is also connected to alternative power sources such as ESS 2800.

[0081] In some embodiments, the ESS 2800 is a multitude of systems working in tandem in which there can be an energy generating system, like a diesel generator, independent from a utility power grid, along with an energy storage system, like a battery, to power or supplement powering a facility. In some embodiments, one or a multitude of battery assemblies 10, within forklifts 130 and pallet jacks 230, may be electrically connected to the charging unit 200 with an appreciable level of charge. These charged and electrically connected battery assemblies 10 may be commanded by the BOSS 600 through an algorithmic determination analyzing current power demands, scheduled battery usage and power need, and overall grid power demand levels, or from a command from the power management controller 806 sent to the BOSS 600 through wireless communications, to discharge stored energy within the cells 710 to the charging unit 200 to minimize the facility’s overall power draw from the power grid. This power diverted from the battery assembly 10 may then be used to charge another battery assembly 10 that is scheduled for usage, or diverted by the controller 806 into the greater facility energy system for use on high demand systems like HVAC 804 to minimize the demand from the external power grid. Thus, in some embodiments, the ESS 2800 may be partially or fully comprised of one or multiple battery assembly 10 which have an appreciable and expendable state of charge that are discharged to minimize demand from the greater power grid. Those with skill in the art will understand a multitude of different battery assemblies, vehicles and charging unit configurations can be used to provide power for a variety of determinative factors both economically driven and generally desirable factors — like a temporary grid shutoff.

[0082] As discussed, the facility in the preferred embodiment is connected to an electrical grid operated by a utility company that generates electricity from a multitude of power sources and transmits that energy over high-voltage lines which are then regulated for commercial and residential use in exchange for money. The electrical grid has a variety of sources, some of which have the capacity to increase or decrease output to match demand and ensure that sufficient energy is available to distribute to customers within the entire grid network. The energy provided is used to power different electrical systems and has a non-uniform demand characterized by large fluctuations in demand throughout a single day, driven by factors like HVAC systems activating and industrial machinery operating during typical working hours. Those with knowledge of the field know these demand peaks often have a cognizable pattern of demand that, through analysis of historical data of previous years usage, can be fairly reliably predicted based on seasonal weather patterns and the correlated demands from industries and residencies within a section on the grid. The day-to-day patterns often are not consistent throughout the year, as seasonal variations also impact the general draw of high demand systems, like HVACs and industrial operations. The corresponding energy supply variations to match demand fluctuations have costs associated with them, and results in non-uniform costs for a set amount of energy to power different systems at differing parts of a single day. For instance, at 3am during a summer month, a typically low energy demand time period when power sources are not required to operate at high capacity, a kilowatt-hour (kWh) may cost $0.15. However, at 5pm during a summer month, a typically high demand time period when power sources are operating at a high capacity, a kWh may cost $0.25. Further, the utility company supplying the energy often will incentivize large energy users during peak demand times to minimize or optimize energy draw by enacting a fee system for their relative power use within peak demand time. Those with skill in the art willunderstand this is an illustrative example of an electrical grid and peak demand, and a multitude of additional factors and incentive enforcements methods can be utilized without departing from the scope of this disclosure.

[0083] Utility companies providing energy often provide the public historical data showing energy usage over year long periods, as well as hour to hour and even minute to minute details throughout the overall period. When available, this information can be used to predict when, on any given day, peak demand periods are likely to be. Utility companies often also provide the public the ability to see real-time data on current demand from the grid, allowing instantaneous access to demand levels. High energy users, like grocery stores with large facilities requiring high powered HVACs and a multitude of refrigeration units for their products, are heavily impacted by the price of energy and often attempt to minimize their average energy costs. By predicting likely to be peak demand periods and supplementing predictions with real time monitoring, high energy users can take informed actions to optimize their energy consumption by stopping or preventing unnecessary power usages to diminish power draw until peak demand energy costs subside. Those with skill in the art will understand a multitude of additional factors and methods can be utilized to monitor, predict and adapt to demand and energy prices without departing from the scope of this disclosure.

[0084] As previously discussed, by its internal antennas 608-616, BOSS 600 is configured for wireless communication on a plurality of networks, any or all of which can be configured to connect to the internet and / or be part of an loT network or wireless communication network. As depicted in Fig. 8, BOSS 600 can communicate over any of a first cellular network 812 (by SIM card 1), a second cellular network 814 (by SIM card 2), or a satellite communication network 816 (by satellite antenna 612). Further, BOSS 600 can communicate over a Wi-Fi network 818 (by Wi-Fi antenna 614) provided by a Wi-Fi router 820 of facility 800. Finally, BOSS 600 can communicate over a Bluetooth connection / network 822 (by Bluetooth antenna 616). BOSS 600 is configured to communicate with any device also connected to these networks or the internet, and in some embodiments, as illustrated, is configured to communicate with controller 806. In other embodiments, BOSS 600 is configured to communicate with facility power supplies such as ESS 2800 and / or configured to control the operation of ESS 2800 via wired or wireless communication. In some embodiments, BOSS 600 is configured to communicate economic data, such as electricity savings and monetary savings that occur as a result of implementing the systems of the current disclosure, to any device also connected to these networks or the internet.

[0085] By connection to BOSS 600 over the internet via one of the networks, controller 806 can obtain real-time data related to battery assembly 10 from BOSS 600 as forklift 130 and / or pallet jack 230 is in use. Specifically, controller 806 can control the operation of HVAC unit 804 based on real-time data related to battery modules 300a-h transmitted. In some embodiments, controller 806 is configured to control the operation of facility power supplies such as ESS 2800 based on real-time data related to battery modules 300a-4 transmitted by BOSS 600. Additionally, controller 806 can send warnings, reminders, or control demands to BOSS 600 to inform the operator of forklift 130 or pallet jack 230 of the operation of the HVAC unit 804, as will be discussed in greater detail below.

[0086] Fig. 10 is a schematic illustrating a communication and control network between a facility asset such as electric pallet jack 230, a charging unit 200, power management controller 806, ESS 2800, and other power drawing systems 805. Each pallet jack 230 is powered by a battery assembly 10, which is equipped with loT technology that enables communication between each control system in the network. As an example, the battery module’s 10 charge level can be relayedto charging unit 200 via loT communication. Furthermore, the charging rate of the charger 200 can be relayed to the power management controller 806, also via loT technology. A plurality of pallet jacks 230, each equipped with a battery assembly 10, may be connected to a charging unit 200 at any given time. The pallet jack 230 charging unit 200 and the other charging units 200a in facility 800 communicates with power management controller 806, which manages the building’s power distribution during peak hours by managing power to a selection of electrical systems in the facility. With the teachings of the current disclosure, the charging rate for each mobile electric device, such as pallet jack 230 as illustrated (or forklift 130, not shown), can be optimized for the duration of the peak power consumption period. As mentioned above, in some embodiments, BOSS 600 can be configured to allow an operator to input charging parameters, such as, but not limited to, schedules, charging rates, or charge thresholds. In some embodiments, BOSS 600 is configured to determine optimized charging parameters based on data retrieved from an operator or data retrieved via wireless or wired connections to systems of the facility. In some embodiments, BOSS 600 is configured to communicate to charging unit 200 the desired charging rate for the associated mobile electric device, such as pallet jack 230 as illustrated (or forklift 130, not illustrated). BOSS 600 may be configured to determine the desired charging rate based on a particular centralized algorithm specific to the mobile electric device, that may include the device’ s duty cycle, charging schedule, energy consumption, and operational data. Those with skill in the art will understand this is a non-exhaustive list of relevant data to determine optimized charging rates.

[0087] In preferred embodiments, the BOSS module includes processing chips that are programmed to control decisions for managing whether and to what extent the full charging poweris available for recharging the battery modules, which is achieved through networked data communication and coordination with the power management system of the larger facility.

[0088] In other embodiments, however, BOSS 600 may be configured to communicate with a separate charging unit 200 to convey information or data related to optimized charging rate for the associated mobile electrical device, such as pallet jack 230 as illustrated (or forklift 130, not illustrated), and in some embodiments, charging unit 200 is configured to determine the optimized charging rate according the information received from the associated electrical asset. For example, once pallet jack 230 is plugged into charging unit 200, charging unit 200 obtains the serial number associated with battery assembly 10 of pallet jack 230, wherein the serial number is associated with a particular charging program. Furthermore, predetermined charge levels of a specific battery 10 can be optimized in such a way that the enables the associated pallet jack 230 (or forklift 130) to operate at a minimum charge level, without surpassing the peak power threshold.

[0089] With reference to Fig. 14, the battery assembly 10 of some embodiments utilizes method 1100 to determine the charge rate of the battery modules 300a-300h. Block 1102 the battery assembly 10 is connected to charging unit 200, at which point block 1103 the BOSS 600 may be configured to determine or receive commands from power management control 806 via loT technology that the charge period is to occur during peak demand period or that the facility demand is peaking, and to command battery modules 3OOa-3OOh to pull a desired charge rate from charger 200. If there is no general demand peak or localized facility demand peak, the battery assembly 10 proceeds to block 1104 to demand the standard rate of charge from charging unit 200 power draw. If block 1103 determines that there is peak demand, the BOSS or external power management system 804, proceeds to block 1105 to determine if the battery assembly 10 has a sufficient state of charge for its next scheduled utilization or if the peak demand period will end with sufficienttime to charge the battery assembly 10 afterward before its next scheduled utilization. If the battery assembly 10 lacks the sufficient charge, it proceeds to block 1106 where it charges at deviated rate from the standard until it achieves the goal state of charge or demand limitations end. Conversely, when one or multiple pallet jacket 230 (or forklift 130) and its associated battery assembly 10 are not scheduled for usage for an extended period or have sufficient charge for the next scheduled usage, the BOSS 600 may command the battery modules 300a-300h to proceed to block 1107 and command no charge, or a significantly lower charger rate to minimize the cumulative facility 800 power consumption and decrease peak energy costs. At any time, the algorithmically determined deviated charge rate can be overridden by process 1108 to charge at a standard charge rate for unscheduled use or expected variation from previous use. Those with skill in the art will understand that alternative methods of data transfer and commands, considerations for altering the charge rate and scheduling can be utilized without departing from the scope of this disclosure.

[0090] The charging parameters may also coincide both with the user’s operation schedule and peak power periods of facility 800. Some embodiments may involve power distribution between charging unit 200 and other large power consuming systems 805. For example, the power supply to other power draw systems 805, like the facility’s HVAC system 802, can be adjusted, thereby allowing charging unit 200 to charge battery assembly 10 without going over the peak power threshold. For example, controller 806 may reduce the operation of the HVAC system 802 or other large power draw systems 805 during the charging of modules 300a-h, and once the charging of modules 300a-h is complete or peak energy has ended, controller 806 may increase the operation of HVAC system 802 or other large power draws 805. Those with skill in the art will recognize that any large power consuming system of facility 800 may be adjusted. In some embodiments, as discussed in more detail below, battery assembly 10 may communicate to ESS 2800, in someembodiments via power management controller 806, to activate ESS 2800 to provide electricity to the facility during charging of battery assembly 10 in order to reduce the amount of electricity drawn from the grid during the charging period.

[0091] Fig. 11 is a flowchart of one embodiment of these disclosures illustrating a method 900 of coordinating control between charging of battery modules 300a-h with charging unit 200 and operation of HVAC system 802. Specifically, as will be understood by those in the art, method 900 allows for facility 800 to minimize its use, or rate of use, of electricity from the grid and can specifically be implemented during peak demand hours to ensure the amount or rate at which electricity is used is within facility’s 800 allotted amount or rate during the peak demand hours. As those with skill in the art will understand, facility’s 800 largest consumers of electricity may be operating HVAC system 802 and charging of modules 300a-h. Charging of modules 300a-h applies an especially large electrical load to the facility’s 800 grid when the facility 800 has a fleet of dozens of forklifts 130, each needing to be charged simultaneously according to scheduled break periods. Charging modules 300a-h while also operating HVAC system 802 may cause facility 800 to draw electricity from the grid at a level greater than its allotted amount and / or rate during peak demands, which may be allotted based on government regulations or industry-specific requirements. Accordingly, in some embodiments, method 900 is implemented to coordinate the supply power to HVAC system 802 and charging of modules 300a-h of a plurality of forklifts 130 operated within a grocery storage facility 800. While method 900 illustrates coordinating control between charging forklifts 130 and operation of HVAC system 802, those with skill in the art will recognize the same method can be applied to coordinating control between charging pallet jacks 230 and operation of HVAC system 802.

[0092] Method 900 can begin at block 902 by operating an HVAC system 802 according to a pre-established or operator-set setting. For example, during working hours of facility 800, an operator may set controller 806 to keep the temperature of the environment of facility 800 at a desired temperature. As such, controller 806 and inside thermometer 808 can be used as a thermostat, as has been previously discussed. As an illustrative example, during a set working period of 8:00AM to 5:00PM, controller 806 can be set to maintain the internal temperature of facility 800 at 72 degrees Fahrenheit to maintain a comfortable and safe environment for employees working in facility 800.

[0093] Method 900 can continue to block 904 by establishing a wireless connection between BOSS 600 and controller 806, such as through connections 812-818 or 822, as has been previously discussed. In some embodiments, certain types of connection may be prioritized over others. For example, in some embodiments, the processor 604 may be programmed to prioritize first communicating with controller 806 via Bluetooth 822 or Wi-Fi 818, and then, if those connection types are for some reason not available, communicating with controller 806 via a cellular or satellite network (networks 812-816). As will be discussed in greater detail below in Fig. 10, processor 604 can utilize method 1000 in choosing which cellular or satellite network 812-816 to use for communicating with controller 806. As previously discussed, in some embodiments, facility may have a fleet of dozens of forklifts 130, and thus step 904, and indeed all of method 900, can be performed in coordination with each of the BOSS 600 of the forklift fleet.

[0094] Method 900 can continue to block 906 by delivering a charging schedule for battery modules 300a-300h during a working shift to controller 806. In some embodiments, the charging schedule can be delivered by being programmed to controller 806 by an operator. In some embodiments, the charging schedule can be saved to a memory of BOSS 600 and can be deliveredby being transmitted to controller 806 by BOSS 600 through the wireless connection established in block 904. As an illustrative example, during a working period of 8:00AM to 5:00PM, a forklift operator will have established break periods throughout the day. During these break periods, battery modules 300a-h are also charged to ensure forklift 130 remains operable throughout the working hours of the day. As an illustrative example, the forklift operator may have a morning break from 10:00AM - 10:15AM, a lunch break from 12:00PM - 1 :00PM, and an afternoon break from 3:00PM - 3: 15PM. Accordingly, in this example, the charging schedule of the battery modules 300a-h coincides with the three scheduled breaks, and would be scheduled for charging from 10:00AM - 10:15AM, 12:00PM - 1 :00PM, and 3:00PM - 3:15PM. Although three charging periods are described, those with skill in the art will understand that this is merely an illustrative example, and according to various embodiments, there are more or less than three breaks of various durations scheduled throughout a working day.

[0095] Method 900 can continue to block 908 by transmitting signals between BOSS 600 and controller 806 through the connection established in block 904. For example, as previously discussed, BOSS 600 can transmit operation and condition data related to modules 300a-h to controller 806 during working hours. As will be discussed in greater detail below, controller 806 can use this data in planning operations of HVAC unit 804, adjusting the scheduled battery module charging periods, and / or planning operations of power supplies such as ESS 2800. In some embodiments, controller 806 can transmit signals to BOSS 600. For example, controller 806 can send signals to BOSS 600 to notify the forklift operator, such as by activating a warning light or hom / chime of the forklift, when a scheduled battery module charging period (discussed in block 906) is approaching.

[0096] Based on the transmission communicated and the scheduled charging periods of block 906, block 908 further includes determining whether one of the scheduled charging periods is approaching. In some embodiments, this determination is performed by controller 806. In other embodiments, this determination can be performed by processor 604 of BOSS module 600 and communicated to controller 806. In some embodiment, the determination that a charging period is approaching is based solely on the charging periods provided to the controller 806 in block 906. In some embodiments, determination that a charging period needs to occur is performed by controller 806 or BOSS 600 based on operation data related to the modules 300a-h. For example, controller 806 or BOSS 600 can recognize that, although a charging period may be scheduled for starting at 10:00AM, the battery modules have a state of charge that will not last until 10:00AM. Accordingly, the controller 806 or BOSS 600 can deliver a signal to forklift 130 that the scheduled charging period has been changed to 9:30AM based on the state of charge of battery modules 300a- h.

[0097] Method 900 can continue to block 910 by determining if any part of the approaching charging period falls within a peak energy demand period for the given day. Again, this determination can be performed by processor 604 of BOSS module 600 or controller 806. Specifically, peak demand periods can be programmed to controller 806, or controller 806 can be provided real-time updates from an electricity provider regarding the peak demand periods for that day through controller’s 806 internet connection. In some embodiments, peak demand periods can be programmed to BOSS module 600, or BOSS module 600 can be provided real-time updates through a wireless communication network. BOSS module can be configured to communicate to controller 806 that a peak energy period is about to occur or is occurring. Accordingly, as an illustrative example, for a given day controller 806 may determine that the peak energy demandperiod is from 1 1 :00AM to 5:00PM. With this information, controller 806, or in some embodiments BOSS module 600, can then determine whether an approaching charging period falls within the peak demand period. For example, for the 10:00AM - 10:15AM charging period, controller 806 would determine that the charging period does not fall within the peak demand period. In this case, method 900 would then proceed to block 912, where controller 806 can continue normal operation of HVAC unit 804 (as defined in block 902) during the charging period while modules 300a-h are being charged by charging unit 200. For example, in other embodiments, for the 10:00AM - 10: 15AM charging period, BOSS 600 can determine that the charging period does not fall within the peak demand period. In this case, BOSS can communicate that information to controller 806, and method 900 would proceed to block 912, where controller 806 can continue normal operation of HVAC unit 804 (as defined in block 902) during the charging period while modules 300a-h of battery assembly 10 are being charged by charging unit 200.

[0098] In some embodiments, those with skill in the art will understand that blocks 910, 912 can be considered optional blocks of method 900. That is, in some embodiments, method 900 does not consider the peak demand period and proceeds from block 908 to block 914.

[0099] Alternatively, in response to determining that an approaching charging period occurs in the peak demand period, such as the charging period starting at 12:00PM discussed above in block 906, method 900 can continue to block 914 by determining a desired pre-cool temperature for the facility 800 and a time period for achieving the pre-cool temperature by HVAC unit 804. In some embodiments, block 914 is performed by HVAC controller 806. However, in other embodiments, block 914 can be performed by BOSS processor 604.

[0100] As discussed in greater detail below, in performing method 900, controller 806 is configured to turn off HVAC unit 804 during charging of modules 300a-h to conserve electricityor reduce the rate of consumption of electricity at a given time. Of course, turning off the HVAC unit 804 for an extended period of time while modules 300a-h charge can lead to undesirable, uncomfortable, and even unsafe temperatures within facility 800. In order to maintain a comfortable and safe working environment, controller 806 can use preprogrammed instructions and / or data from thermometers 808, 810 to determine a pre-cool temperature to cool the environment of facility 800 before the charging period when the HVAC unit 804 is turned off. For example, in block 902, controller 806 can be programmed to maintain the inside temperature of facility 800 at 72 degrees Fahrenheit. Controller 806 may be preprogrammed to pre-cool the facility to 70 degrees (i.e., lowering the internal temperature by 2 degrees) before the 12:00PM - 1 :00PM charging period of modules 300a-h in order to prepare for the hour-long shut down of HVAC unit 804, thereby offsetting at least some of the expected temperature rise within facility 800 during that hour, and thus maintaining a comfortable and safe working environment within the facility 800. In some embodiments, controller 806 may be preprogrammed to pre-cool the pre- established environment temperature setting by a certain amount before each charging period, such as the 2 degrees Fahrenheit previously discussed. In some embodiments, controller 806 can be configured to determine an appropriate amount to pre-cool facility 800 for a given charging period based on readings from thermometers 808, 810. For example, on a day in which outdoor temperatures taken by thermometer 810 are measured at 100 degrees Fahrenheit, controller 806 can determine that a greater amount of pre-cooling of facility 800 is needed than compared to a day in which outdoor temperatures are measured at 80 degrees in order to offset the faster rate at which temperatures will rise within facility 800 on the 100 degree day. Accordingly, in such embodiments, controller 806 may determine that it is appropriate to pre-cool the environment by 5 degrees Fahrenheit rather than the typical 2 degrees of pre-cooling.

[0101] Additionally, controller 806 can determine or estimate the amount of time it will take to achieve the determined pre-cool temperature. In some embodiments, controller 806 can simply be programmed to start the pre-cooling of the environment at a set time before the scheduled charging period, such as, for example, 30 minutes before the scheduled charging period. In other embodiments, controller 806 can estimate the amount of time HVAC unit 804 will need to achieve the desired precool -temperature in the environment based on data related to the HVAC unit and data from thermometers 808, 810. For example, as those with skill in the art will understand, when external temperatures are extremely high, the HVAC unit 804 may need more time to cool the environment of facility 800 to the desired pre-cool temperature than when external temperatures are mild.

[0102] As those with skill in the art will understand, although throughout method 900 and specifically in block 914, operations for “pre-cooling” of facility 800 is described, method 900 can also be used to “pre-heat” when facility 800 is in a cold-weather environment where external temperature are low. Typically, for large facilities, HVAC units 804 are primarily used to battle the heat, especially in grocery storage facilities disclosed herein where food must be kept below a certain temperature to avoid spoiling, which is why this disclosure uses pre-cooling as an illustrative example. However, those with skill in the art will recognize how the same method and steps discussed herein can be used to battle cold-weather environments by performing analogous pre-heating procedures.

[0103] Method 900 can continue to block 916 by, in response to determining that the pre-cool period established in block 914 has begun, activating the HVAC unit 804 to achieve the pre-cool temperature. For example, controller 806 can determine that in order to achieve a pre-cool temperature of 70 degrees Fahrenheit from a normal operating temperature of 72 degreesFahrenheit, controller 806 needs to start operating the HVAC unit 804 at a full cooling operating condition at 11 :30AM in order to achieve the 70 degree Fahrenheit pre-cool temperature by the 12:00PM charging period start time. Thus, in block 916, at 11 :30AM controller 806 activates unit 804 to achieve the desired 70-degree pre-cool temperature.

[0104] Method 900 can continue to block 918 where, in response to determining that the charging period established in block 906-908 has begun, HVAC unit 804 is turned off and charging modules 300a-h with charger 200 begins. Continuing the example discussed above, in response to determining the time is 12:00PM (the start time of the charging period), controller 806 turns off HVAC unit 804, and in some embodiments, BOSS 600 can signal to controller 806 to initiate the deactivation of HVAC unit 804. As previously discussed, this is done so that the amount of electricity or the rate of electricity used by facility 800 from the grid is conserved while charging modules 300a-300h. In some embodiments, controller 806 determines that the charging period has begun solely from determining that the start time for starting the given charging period has occurred (i.e., the time is 12:00PM). In some embodiments, controller 806 determines that the charging period has begun based on information communicated by BOSS 600 such as, for example, charging schedules. In some embodiments, alternatively or in addition to determining that the start time for the charging period has occurred, controller 806 is configured to receive a signal from BOSS 600 indicating or confirming that module 300a-h are coupled with charging unit 200 (also called a charger) are ready for or already started charging. In response to receiving this message, controller 806 can turn off HVAC unit 804. In some embodiments, in response to determining that the start time for the charging period has occurred, ESS 2800 is configured to receive a signal from BOSS 600, or from controller 806 in some embodiments, indicating or confirming that module 300a-h are coupled with charger 200 are ready for or already startedcharging. In response to receiving this message, ESS 2800 is configured to supply electricity during the charging period to reduce the amount of electricity used by the facility 800 from the grid during the charging of modules 300a-300h.

[0105] In some embodiments, controller 806 can receive a signal from BOSS 600 indicating that battery assembly 10 has been plugged into charger 200 and requesting permission from controller 806 to initiate charging. Controller 806 can then grant permission to BOSS 600 to initiate charging in response to determining that the charging period has begun and that HVAC unit 804 is turned off. In some embodiments, controller 806 can determine that the charging period has begun in response to receiving messages from a plurality of the BOSS’s 600 that their respective battery assembly’s 10 are plugged in with a charger 200 and awaiting charging. As noted, facility 800 may employ dozens or even 100 or more forklifts 130 in some embodiments, and controller 806 may determine that it is proper to initiate the charging session in response to determine that a certain percentage (such as 25%, for example) of the forklifts are plugged in to a charger 200 and awaiting charging. In some embodiments, in response to determining that a certain percentage (such as 25%, for example) of the forklifts are plugged into charging unit 200 and awaiting charging, ESS 2800 is configured to receive a signal from a plurality of BOSS’s 600, or from controller 806 in some embodiments, that their respective battery assembly’s 10 are plugged in to charging unit 200 and awaiting charging. In response to receiving this message from a plurality of BOSS’s 600 or from controller 806, ESS 2800 is configured to supply electricity during the charging period to reduce the amount of electricity used by the facility 800 from the grid during the charging of modules 300a-300h.

[0106] Further, alternatively or in addition to the previously discussed ways of determining that the charging period has begun, in some embodiments, controller 806 can use readings from internalthermometer 808 in making this determination. Using the example previously discussed, if 12:00PM (the start of the charging period) occurs and thermometer 808 detects the inside of facility 800 is only 71 degrees Fahrenheit rather than the desired pre-cool temperature of 70 degrees, 806 controller 806 can decide to delay the start of the scheduled 12:00PM charging period until the 70 degree target temperature is achieved. In these embodiments, controller 806 can send a signal to BOSS 600 to indicate to the driver through a display, light, or chime / horn of forklift 130 that the start of the scheduled charging period has been delayed and not to start charging of the battery modules 300a-300h until controller 806 sends a signal indicating that the charging period can begin. Controller 806 can then send a signal to BOSS 600 that the charging period can begin in response to determining that the desired pre-cool temperature of 70 degrees has been achieved. In some embodiments, controller 806 or BOSS 600 can signal to ESS 2800 that the charging period can begin, and ESS 2800 is then configured to provide electricity to facility 800 and / or charging unit 200 during the charging period to reduce the amount to electricity used by the facility 800 from the grid during the charging period.

[0107] Method 900 can continue to block 920 by, in response to determining that the charging period has ended and thus charging of battery modules 300a-300h has ended, turning HVAC unit 804 back on according to a pre-established desired setting for facility 800. For example, in some embodiments, after the charging period has ended, controller 806 can turn HVAC unit 804 back on with instruction to cool facility 800 to the temperature established in 902. In some embodiments, controller 806 determines that the charging period has ended based solely on determining that the time for the charging period is complete. For example, using the previously discussed illustration, in response to determining that it is 1 :00PM and thus that the 12:00PM - 1 :00PM charging period has ended, controller 806 can turn HVAC unit 804 back on. Alternatively,or in addition to determining the charging period is completed based on the time, in some embodiments, controller 806 receives a signal from BOSS 600 indicating that charging of modules 300a-h has been completed and in response to receiving this signal, controller 806 turns HVAC unit 804 back on. In other embodiments, once charging of modules 300a-h has been completed, BOSS 600 can initiate the reactivation of HVAC unit 804 by signaling to controller 806 to turn HVAC unit 804 back on. In some embodiments, controller 806 or BOSS 600 can signal to ESS 2800 that the charging of modules 300a-h has been completed, and in response to receiving that signal, ESS 2800 is configured to shut off or reduce the amount the electricity provided to facility 800 and / or charging unit 200.

[0108] Additionally, in some embodiments, controller 806 can activate HVAC unit 804 in response to determining that the peak demand period has expired or ended. For example, in some embodiments, a peak demand period for a given day may be from 11 :00AM - 4:00PM, and a charging period for modules 300a-h for that day may be from 3:45pm - 4: 15PM. Thus, in this example, the peak demand period expires before the charging period. In this embodiment, in response to detecting that the peak demand period has ended by determining that the time of day is 4:00PM, controller 806 can turn HVAC unit 804 back on according to pre-established settings, as has been previously discussed. In some embodiments, controller 806 receives a signal from BOSS 600 that the peak demand period expires and in response to receiving this signal, controller 806 turns HVAC unit 804 back on. In some embodiments, BOSS 600 determines that the peak demand period has expired using the same example as provided above, in response to determining that the peak demand period has expired, BOSS 600 can initiate the reactivation of HVAC unit 804 by signaling to controller 806 to turn HVAC unit 804 back on. In some embodiments, controller 806 or BOSS 600 can signal to ESS 2800 that the peak demand period has ended, andin response to receiving that signal, ESS 2800 is configured to shut off or reduce the amount the electricity provided to the facility.

[0109] Those with skill in the art will understand that although block 902-920 are shown as occurring in a certain order, blocks 902-920 can be performed according to a number of different orders without departing from the scope of this disclosure. Additionally, certain blocks 902-920 can be removed from method 900 and / or certain additional steps can be added without departing from the scope of this disclosure. Additionally, as previously mentioned and will be understood by those in the art, the various calculations, controlling operations, and estimations performed in method 900 can be performed by either of controller 806, processor 604 of BOSS module 600, or a combination thereof according to various embodiments of this disclosure.

[0110] Fig. 12 is a flowchart of one embodiment of this disclosure illustrating a method 950 for coordinating control of the charging rate of battery modules 300a-h. Specifically, as will be understood by those in the art, method 950 allows for facility 800 to minimize its use, or rate of use, of electricity from the grid and can implemented during peak demands hours to ensure the amount or rate at which electricity is used within facility’s 800 allotted amount or rate during the peak demand hours. Those with skill in the art will understand that facility 800 may be operating large power draws during the charging of modules 300a-h. Charging of modules 300a-h applies a large electrical load to the facility’s 800 grid when facility 800 has a fleet of dozens of electrical vehicle assets 130, 230 each needing to be charged simultaneously according to the scheduled charging periods. Charging modules 300a-h while also operating other large power draws may cause facility 800 to draw electricity from the grid at a level greater than its allotted amount and / or rate during peak demands, which may be allotted based on government regulations or industryspecific requirements. Accordingly, in some embodiments, method 950 is implemented tooptimize charging of modules 300a-h of a plurality of mobile electric devices 130, 230 operated within a facility 800. One with skill in the art will recognize that this method can be utilized for any mobile electric device other than electric vehicles.[0U1] Method 950 can begin at block 951 by establishing a wireless connection between BOSS 600 and power management controller 806, such as through connections 812-818 or 822, as has been previously discussed. In some embodiments, certain types of connection may be prioritized over others. For example, in some embodiments, the processor 604 may be programmed to prioritize first communicating with controller 806 via Bluetooth 822 or Wi-Fi 818, and then, if those connection types are for some reason not available, communicating with controller 806 via a cellular or satellite network (networks 812-816). As will be discussed in greater detail below in Fig. 13, processor 604 can utilize method 1000 in choosing which cellular or satellite network 812- 816 to use for communicating with controller 806. As previously discussed, in some embodiments, facility may have a fleet of dozens of mobile electric devices (for example, electric vehicles 130, 230) and all of method 950 can be performed in coordination with each of the BOSS 600 of the fleet.

[0112] Method 950 can continue to block 952 by delivering a charging schedule for battery modules 300a-300h during a working shift to controller 806. In some embodiments, the charging schedule can be delivered by being programmed to controller 806 by an operator. In some embodiments, the charging schedule can be saved to a memory of BOSS 600 and can be delivered by being transmitted to controller 806 by BOSS 600 through the wireless connection established in block 951. As an illustrative example, during a working period of 8:00AM to 5:00PM, an electric vehicle operator, such as an operator of pallet jack 230 or forklift 130, will have established break periods throughout the day. During these break periods, battery modules 300a-h may becharged to ensure the electric vehicle 130, 230 remains operable throughout the working hours of the day. As an illustrative example, an electric vehicle operator may have a morning break from 10:00AM - 10: 15AM, a lunch break from 12:00PM - 1 :00PM, and an afternoon break from3:00PM - 3: 15PM. Accordingly, in this example, the charging schedule of the battery modules 300a-h coincides with the three scheduled breaks, and would be scheduled for charging from 10:00AM - 10: 15AM, 12:00PM - 1 :00PM, and 3:00PM - 3: 15PM. Although three charging periods are described, those with skill in the art will understand that this is merely an illustrative example, and according to various embodiments, there are more or less than three breaks of various durations scheduled throughout a working day. Additionally, one with skill in the art will understand that the facility’s 800 electric vehicles 130, 230 may be charged during hours facility 800 is closed, such as, for example, after 5:00PM or before 8:00AM.

[0113] Method 950 can continue to block 953 by transmitting signals between BOSS 600 and controller 806 through the connection established in block 951. For example, as previously discussed, BOSS 600 can transmit operation and condition data related to modules 300a-h to controller 806 during working hours. As will be discussed in greater detail below, controller 806 can use this data in planning operations of electric vehicles 130, 230 and / or adjusting the scheduled battery module charging periods. In some embodiments, controller 806 can transmit signals to BOSS 600. For example, controller 806 can send signals to BOSS 600 to notify the electric vehicle 130, 230 operator, such as by activating a warning light or hom / chime of the electric vehicle 130, 230, when a scheduled battery module charging period (discussed in block 952) is approaching.

[0114] Based on the transmission communicated and the schedule charging periods of block 952, block 953 further includes determining whether one of the scheduled charging periods is approaching. In some embodiments, this determination is performed by controller 806. In otherembodiments, this determination can be performed by BOSS processor 604 and communicated to controller 806. In some embodiments, the determination that a charging period is approaching is based solely on the charging periods provided to the controller 806 in block 952. In some embodiments, determination that a charging period needs to occur is performed by controller 806 or BOSS 600 based on operation data related to the modules 300a-h. For example, controller 806 or BOSS 600 can recognize that, although a charging period may be scheduled for starting at 10:00AM, the battery modules have a state of charge that will not last until 10:00AM. Accordingly, the controller 806 or BOSS 600 can deliver a signal to electric vehicle 130, 230 that the scheduled charging period has been changed to 9:30AM based on the state of charge of the battery modules 300a-h.

[0115] Method 950 can continue to block 954 by determining if any part of the approaching charging period falls within a peak energy demand period for the given day. Again, this determination can be performed by BOSS 600 via processor 604 or by controller 806. Specifically, peak demand periods can be programmed to controller 806, or controller 806 can be provided realtime updates from an electricity provider regarding the peak demand periods for that day through controller’s 806 internet connection. In some embodiments, peak demands periods can be programmed to BOSS 600, or BOSS 600 can be provided real-time updates from an external system via a wireless connection. Accordingly, as an illustrative example, for a given day controller 806 (or BOSS 600) may determine that the peak energy demand period is from 11 :00AM to 5:00PM. With this information, controller 806 (or BOSS 600) can then determine whether an approaching charging period falls within the peak demand period. For example, for the 10:00AM - 10: 15AM charging period, controller 806 (or BOSS 600) would determine that the charging period does not fall within the peak demand period. In this case, method 950 would then proceedto block 955, where charging unit 200 can charge modules 300a-h at a pre-established setting, an operator-set setting, or a desired charging rate established by or according to BOSS 600 (as previously discussed in Fig. 10) or controller 806.

[0116] In some embodiments, those with skill in the art will understand that blocks 954, 955 can be considered optional blocks of method 950. That is, in some embodiments, method 950 does not consider the peak demand period and proceeds from block 953 to block 956.

[0117] Alternatively, in response to determining that an approaching charging period occurs in the peak demand period, method 953 can continue to block 956 by the BOSS 600 determining, and / or the controller 806 determining and communicating to the BOSS 600 an adjusted charging rate for battery modules 300a-h to pull from charging unit 200 for the charging. Those with skill in the art will understand the charging rate can be adjusted before charging modules 300a-h begins or during the charging of modules 300a-h. In some embodiments block 956 is performed by controller 806. For example, controller 806 can determine that in order to achieve X kW / hours of charge, controller 806 needs to command the BOSS 600 to command the battery modules 300a-h to adjust the charging rate to X at X time. However, in other embodiments, block 956 can be performed by BOSS processor 604. For example, BOSS processor 604 can determine that in order to achieve X kW / hours of charge, BOSS 600 needs to adjust the charging rate to X at X time. One with skill in the art will understand that charging rate can be adjusted to a lower rate than the predetermined rate or a faster rate than the pre-determined rate depending on factors related to facility 800 or modules 300a-h. Additionally, in some embodiments, BOSS 600 communicates to controller 806 that a certain power supply is demanded for the charging of modules 300a-h. Similar to process 950, the power supply power supply to large power draws, such as HVAC system 802 or other power draws 805, can then be adjusted to allow a desired charging rate for chargingmodules 300a-h, without going over the facility’s 800 peak power threshold during peak power periods.

[0118] Method 950 can continue to block 957 where, in response to determining that the charging period established in block 952-953 has begun and a charging rate has been determined in block 956, charging of modules 300a-h with charging unit 200 begins. In some embodiments, controller 806 (or BOSS 600) determines that the charging period has begun solely from determining that the start time for starting the given charging period has occurred (i.e., the time is 12:00PM). In some embodiments, alternatively or in addition to determining that the start time for the charging period has occurred, controller 806 is configured to receive a signal from BOSS 600 indicating or confirming that module 300a-h are coupled with charger 200 are ready for or already started charging. In some embodiments, in response to determining that a charging period has begun, BOSS 600 or controller 806 can signal the facility’s 800 alternative power supply 2800 to activate and provide electricity to the facility during the charging period to reduce the amount of electricity drawn from the grid during the charging period.

[0119] In some embodiments, controller 806 can receive a signal from BOSS 600 indicating that battery assembly 10 has been plugged into charger 200 and requesting permission from controller 806 to initiate charging. Controller 806 can then grant permission to BOSS 600 to initiate charging in response to determining that the charging period has begun and that a desired charging rate has been determined. In some embodiments, controller 806 can determine that the charging period has begun in response to receiving messages from a plurality of the BOSS’S 600 that their respective battery assembly’s 10 are plugged in with a charger 200 and awaiting charging. As noted, facility 800 may employ dozens or even 100 or more electric vehicles 130, 230 in some embodiments, and controller 806 may determine that it is proper to initiate the charging session inresponse to determine that a certain percentage (such as 25%, for example) of forklifts 130 and / or pallet jacks 230 are plugged in to a charger 200 and awaiting charging. In some embodiments, in response to determining that a certain percentage (such as 25%, for example) of forklifts 130 and / or pallet jacks 230 are plugged into charging unit 200 and awaiting charging, ESS 2800 is configured to receive a signal from a plurality of BOSS’S 600, or from controller 806 in some embodiments, that their respective battery assembly’s 10 are plugged in to charging unit 200 and awaiting charging. In response to receiving this message from a plurality of BOSS’S 600 or from controller 806, ESS 2800 is configured to supply electricity and notify the controller 806 and / or the plurality of BOSS 600’s they have permission to begin charging during the charging period to reduce the amount of electricity used by the facility 800 from the grid during the charging of modules 300a- 300h.

[0120] Method 950 can continue to block 958 by, in response to determining the peak demand period has ended or expired, controller 806 or BOSS 600 can adjust the charging rate of modules 300a-h. For example, in some embodiments, a peak demand period for a given day may be from 11 :00AM - 4:00PM, and a charging period for modules 300a-h for that day may be from 3 :45pm - 4:15PM. Thus, in this example, the peak demand period expires before the charging period. In this embodiment, in response to detecting that the peak demand period has ended by determining that the time of day is 4:00PM, controller 806 or BOSS 600 can adjust the charging rate according to pre-established settings, as has been previously discussed. In some embodiments, controller 806 or BOSS 600 can signal to ESS 2800 that the peak demand period has ended, and in response to receiving that signal, ESS 2800 is configured to shut off or reduce the amount the electricity provided to the facility, or begin the ESS 2800 power procedure for storing power during economically advantageous periods. Additionally, in response to determining that the chargingperiod has ended and thus charging of battery modules 300a-h has ended, controller 806 determine and command BOSS 600, or in some embodiments BOSS 600 can independently determine to, command modules 300a-300h to stop drawing energy from charging unit 200 and, in some embodiments, controller 806 or BOSS 600 can communicate to ESS 2800 to shut off or reduce the amount of electricity provided by ESS 2800, or begin the ESS 2800 power procedure for storing power during economically advantageous periods. Those with skill in the art will understand that a variety of permutations of the actions above and alternatives can be performed without departing from the scope of this disclosure.

[0121] In addition to monitoring and responding to economic incentives, Figure 15 illustrates how the BOSS module 600 can communicate data to power management system 806 of suboptimal battery module 300a-300h conditions, such as extreme temperatures, state of charge levels outside recommended ranges, and unnecessary charging cycles which will impact the performance and longevity of the battery modules 300a-300h. Those with skill in the art will understand that the listed conditions and impacts are not exhaustive lists of all monitored and reported parameters. Through the provision of this data, users can reliably determine battery health as well as the appropriateness of battery 10 for the application. For example, if the battery modules 300a-300h routinely cycle to a state of charge below 20% state of charge during their scheduled usage, an alternative battery assembly 10 with an increased capacity could be recommended. Alternatively, if a battery assembly 10 routinely discharges down to only 75% before the end of a scheduled usage and subsequent charge, a recommendation to prevent unnecessary charging could be promulgated to minimize charge cycles and maximize battery lifespan, or a recommendation to replace the battery with a lower capacity battery suited to the application. Through the data provided by the BOSS 600, the BOSS 600 or the power management system 806 from dataprovided by the BOSS 600, can then provide recommendations regarding the scheduled utilization of electric vehicle 130, 230 to increase battery module 300a-300h performance and lifespan, prevent unnecessary battery module 300a-300h charging during peak demand periods, and provide information on the appropriateness of the battery 10 capacity relative to its regular schedule needs.

[0122] With reference now to Fig. 15, in some embodiments, the BOSS 600 utilizes process 1200 to communicate using wireless connections regular updates regarding the health of each battery module 300a-300h, the battery cells 710 therein, and other subsystems within battery assembly 10 or the electrical vehicle 130, 230. During routine utilization, process 1202 repeats as the BOSS 600 collects data from the battery modules 3OOa-3OOh and other electrical subsystems. If, for instance one or more battery module 300a-300h has entered a fault state and is no longer charging or discharging, the BOSS 600 determines in process 1203 this fault has occurred and in process 1204 communicates this condition for maintenance via wireless communications or through the display assembly 307 while also determining if the remaining state of charge of the in-service modules 300a-300h is sufficient to complete the remaining schedule based on historic power usage. The BOSS 600 continues to process 1205 to analyze and communicate using wireless connections if a single battery module 300a-300h is performing in a manner different from its sibling modules, and is indicative of calibration issues, connection issues, or other faulty states that may result in a suboptimal performance or lifespan. Those with skill in the art will understand that these lists are not exhaustive indicators of performance issues or undesirable resulting conditions. Process 1205 is expansive and the BOSS 600 determines if various other subsystems such as fan operation 106a-106d and battery indicator 307 are in optimal condition through their wired connections to BOSS 600. Those with skill in the art will understand these examples are illustrative and not exhaustive of systems in communication and under the command of the BOSS600. If process 1205 determines no suboptimal conditions are found, no action occurs in process 1206. BOSS 600 in process 1205 may determine, through variations in performance or failures to respond to commands from connected subsystems, that the system is in a suboptimal condition and requires maintenance. In process 1207, the BOSS 600 or an external system can communicate this information through wireless connection to the power management system 806 or through other notification methods. In some situations the BOSS 600 may determine that the suboptimal condition can be corrected internally and process, and actions are taken and notification of the issue and corrective action taken. The BOSS 600’s data and indications of faulty conditions can be used to notify the user of the battery’s inability to complete scheduled tasks resulting from the faulty subsystem or suboptimal performance condition, correct environmental or other use conditions causing suboptimal condition, or to request preventative maintenance to prevent overall battery 10 deterioration.

[0123] Those with skill in the art will understand that although block 951-958 are shown as occurring in a certain order, blocks 951-958 can be performed according to a number of different orders without departing from the scope of this disclosure. Additionally, certain blocks 951-958 can be removed from method 950 and / or certain additional steps can be added without departing from the scope of this disclosure. Additionally, as previously mentioned and will be understood by those in the art, the various calculations, controlling operations, and estimations performed in method 950 can be performed by either of controller 806, BOSS 600 via processor 604, or a combination thereof according to various embodiments of this disclosure.

[0124] Fig. 13 is a flowchart illustrating a method 1000 performed by processor 604 for establishing connection with a cellular or satellite communication network 812-816, according to an embodiment of this disclosure. As previously discussed, according to various embodiments, theprocessor 604 can be programmed to prioritize communicating via Bluetooth connection 822 and / or Wi-Fi connection 818, and to only use cellular and satellite networks 812-816 if the Bluetooth 822 or Wi-Fi 818 networks are not available for connection. In response to the Bluetooth 822 or Wi-Fi 818 networks not being available, processor 604 can perform method 1000 to determine which of the cellular and satellite networks to use for communication.

[0125] The wide area network determination process 1000 starts at Step 1002, when an operating session of BOSS 600 is activated. At Step 1004, processor 604 of BOSS 600 determines which communication network options are enabled (the “Enabled Network Options”) and what is their Order of Priority for use by BOSS 600. According to some embodiments the enabled networks options are the first and second cellular networks in communication with antennas 608, 610 and the satellite network in communication with satellite antenna 612, previously discussed. By “Order of Priority”, we mean the order in which the networks should be tried, ordered from 1 to n where “n” is the total number of Enabled Network Options. But, before determining the ultimate Order of Priority, processor 604 first determines which networks qualify as Enabled Network Options. This “Enabled” determination considers software settings stored in memory as well as whether SIM-comparable data populated for the corresponding network options. The corresponding software settings are stored in memory registries as either “Enabled” or “Disabled”, a setting that can be pre-programmed in memory or adjusted over the air during reconfiguration sessions. By determining whether SIM-comparable data is populated for the corresponding network option, processor 604 essentially is detecting, for cellular networks, whether the corresponding cellular network has a SIM card installed. If no SIM-comparable data is populated for the cellular network, then there is no SIM card installed, and the corresponding network is resolved to not be an Enabled Network Option. For a satellite network, there generally is no SIMcard, but if the satellite network module is installed, that module contains its own SIM-comparable data, such that a satellite network is always “Enabled” so long as the software settings indicate as much.

[0126] As reflected elsewhere in these descriptions, preferred embodiments are routinely provided with three Enabled Network Options - such as, for example, cellular 1, cellular 2 and satellite - such that “n” would be 3. And, by default, the Order of Priority for those three options is as follows: Network(l) as the cellular network for the carrier with the lowest rate for the times and the location of forklift 130 or pallet jack 2200; Network(2) as the other cellular carrier’s network; and Network(3) as the satellite network. Rather than being limited to the preferred embodiments, though, Fig. 10 depicts that aspect as “Network(l), Network(2), . .. Network(n)” in Step 1004, recognizing that “n” may be more than three in alternative embodiments. Further, although the default Order of Priority is based on price, the main processor 604 is also programmed to enable over-the-air reprioritization of the Order of Priority, if desired, such as if certain lower cost network options are suspected of being unreliable when such unreliability is more risky than the risk of paying more.

[0127] Hence, as described in the immediately foregoing paragraphs, preferred embodiments determine which communication networks are both (i) installed with SIM cards (or populated with comparable SIM data tables in the case of satellite modules) and (ii) have corresponding software settings that indicate whether the respective network is otherwise enabled for use, all as a background part of Step 1004 of the process depicted in Fig. 13. And, then, of those networks that are determined to be Enabled Network Options, Step 904 then determines the corresponding Order of Priority for those Enabled Network Options. As described, that Order of Priority is based on defaults or, if the defaults have been updated, then the latest update for preferred priorities as storedin non-volatile memory. Accordingly, the Order of Priority may effectively be updated by remote controller 806 or based upon an algorithm depending on lowest cost or other variables at any of the forklift’s 130 location (per GPS module on board) and based on the current time of day.

[0128] Irrespective, once the Order of Priority for the Enabled Network Options {Networks(l)- (n)} is determined in Step 1004, the process of Fig. 13 proceeds through Steps 1006, 1008, 1010 & 1012 (collectively, the “Connection Testing Steps”) to test which of the Enabled Network Options can be connected, testing each in the determined Order of Priority until a suitable connection is established over one of those Enabled Network Options. More specifically, Step 1006 is illustrated as first setting two counters - “T” for Tries (as in how many tries has the system attempted for all of the Enabled Network Options) and “N” for Network (as in which of the Enabled Network Options is it testing now) - setting both of the counters to initially be equal to one. Then, the rest of the Connection Testing Steps proceed to test each of the Enabled Network Options in the Order of Priority, trying each of them for a preset number of tries (“TMAX”, as referenced in Step 1010). So, starting with the first network in the Order of Priority (i.e., “Network(i)”), the processor 604 attempts to connect with each network at Step 1008, then attempts each of the others in the Order of Priority and does that whole process for TMAX number of tries without interruption.

[0129] However, if a viable connection with a network has still not been successful after TMA tries, Step 1008 then causes processor 604 to suspend further testing for a Pre-Set Duration (“ti”) as shown in Step 1010. Only as examples, ti might be pre-set as low as one minute or as high as 24 hours, depending on preference. Or, the pre-set ti might be variable based on other factors such that ti is determined by an algorithm. Whatever the pre-set time is, the effect is that, after the main microprocessor 604 has tried all Enabled Network Options TM X times (which is also a pre-setduration according to defaults, inputs and / or multiple factors according to an algorithm), it then suspends further tries for a ti period of time, after which it starts over with its tries, starting again with Network(l) in the Order of Priority.

[0130] After selection of a communication network based on the two criteria already mentioned (Order of Priority and, effectively, signal strength), at Step 1014, BOSS 600 will then use that Network for another Pre-Set Duration of time (t2), which may also be set according to preference. Then during Step 1014, if the duration t2 is reached, the microprocessor 604 then starts the Network Testing Process again (Step 1016) to see if it should switch communications to another network. Or, if the session ends (Step 1018), which may be in the form of signal failure before reaching the t2 Pre-Set Duration, then the entire process 1000 begins again with the next session. It should be understood that, although the switching between communication networks performed by BOSS 600 is performed according to the described criteria, other criteria may be used as understood by one of ordinary skill in the art.

[0131] While the foregoing descriptions and drawings should enable one of ordinary skill to make and use what is presently considered to be the best mode of the invention, they should be regarded in an illustrative rather than a restrictive manner in all respects. Those of ordinary skill will understand and appreciate the existence of countless modifications, changes, variations, combinations, rearrangements, substitutions, alternatives, design choices, and equivalents (“Alternatives”), most if not all of which can be made without departing from the spirit and scope of the invention.

[0132] Therefore, the invention is not limited by the described embodiments and examples but, rather, encompasses all possible embodiments within the valid scope and spirit of the invention as claimed, as the claims may be amended, replaced or otherwise modified during the course of

Claims

related prosecution. Any current, amended, or added claims should be interpreted to embrace all further modifications, changes, rearrangements, substitutions, alternatives, design choices, and embodiments that may be evident to those of skill in the art, whether now known or later discovered. Still other alternatives will be evident to those of ordinary skill in the art. In any case, all equivalents should be considered within the scope of the invention, to the extent expressly disclaimed during prosecution or to the extent necessary for preserving validity of particular claims in light of the prior art.CLAIMSWHAT IS CLAIMED IS:

1. A power management system for coordinating power demands in a facility during peak energy demand periods, said power management system comprising: a. a mobile electric device, said device comprising a rechargeable battery assembly configured to provide power to said device, said mobile electric device comprising: i. a plurality of battery modules; and ii. a control module comprising a processor electrically coupled to said plurality of battery modules, said control module configured to: control operations of said battery assembly; communicate information related to said battery assembly over a wireless communication network, wherein said information is related to a charging period of said battery assembly; determine whether said charging period is likely to occur within a peak energy demand period: and in response to determining that said charging period is likely to occur within a peak energy demand period, initiate a power management strategy for reducing the risk of peak demand penalties.

2. The power management system of Claim 1, wherein said power management strategy includes delaying recharge of said mobile electric device until a time when there is less risk of peak demand penalties.

3. The power management system of Claim 1, wherein said power management strategy includes controlling an HVAC power load to reduce a temperature in the facility before enabling recharge of said battery assembly and, when a lower temperature has been achieved in the facility, then causing deactivation of said HVAC power load and contemporaneously allowing recharge of saidbatery assembly.

4. The power management system of Claim 1, wherein said control module is further configured to determine a desired charging rate to charge said batery assembly and communicate said charging rate to a charging unit in said facility, with which said mobile electric device is operatively connected for recharging said batery assembly.

5. Tire power management system of Claim 4, wherein said control module is configured to determine said desired charging rate based on at least one of said batery assembly’s duty cycle, charging schedule, energy consumption, or operational data.

6. The power management system of Claim 4, wherein said control module is further configured to adjust said desired charging rate before the charging of said batery assembly begins or during the charging of said batery assembly.

7. The power management system of Claim 1. wherein control module further comprises an internal communication circuity disposed within an interior of said batery assembly, wherein said communication circuity is configured to communicate over said wireless communication network.

8. Tire power management system of Claim 1, wherein said control module further comprises an assembly display pad configured to display bate ' assembly operation data to a user, wherein said display pad comprises an interface configured to allow said user to perform operations associated with said batery assembly, wherein said control module is disposed within said mobile electric device in a position where said display pad is exposed to an outside of said device.

9. The power management system of Claim 1, wherein said mobile electric device comprises a forklift.

10. The power management system of Claim 1, wherein said mobile electric device comprises a pallet jack.

671. A power management system for coordinating power demands in a facility during peak energy demand periods, wherein said system includes a plurality of charging units configured to supply electric power to a plurality of power loads, said system further comprising: a. a mobile electric device, said device comprising a rechargeable battery assembly configured to provide power to the device, wherein said battery assembly comprises: i. a plurality of battery modules; and ii. a control module comprising a processor electrically coupled to said plurality of battery modules, said control module configured to:1 . control operations of said battery assembly and communicate information related to said battery assembly operations or battery assembly health over a wireless communication network, wherein said information includes a desired charging rate to charge said battery assembly during a charging period;2. determine if said charging period occurs within a peak energy demand period;3. in response to determining that said charging period occurs within said peak energy demand period, initiate a first adjustment of operations of said power loads during said charging period or delaying charging altogether if the period is sufficient to effectively charge the battery outside of the peak demand period; and4. in response to detennining that said charging period has ended or said peak energy demand period has ended, initiate a second adjustment of operations of said power loads.68

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