Battery swapping system for electric vehicles

Abstract

Systems and methods for swapping batteries in electric vehicles utilize lifting mechanisms integrated into a battery assembly. The lifting mechanisms are electrically powered actuators that raise and lower the battery assembly so that the battery assembly can be mounted and dismounted from an electric vehicle.

Description

BATTERY SWAPPING SYSTEMFOR ELECTRIC VEHICLESTECHNICAL FIELD

[0001] The present description relates generally to electric vehicles, and in particular to electric vehicles used in mining environments.BACKGROUND

[0002] Electric vehicles may operate with one or more electric motors powered by batteries. Batteries in electric vehicles, such as cars and other kinds of vehicles, may be large and heavy. Removing and replacing batteries may require external infrastructure such as cranes, lifts, or other systems. In mining environments, there may be limited space for accommodating external infrastructure.

[0003] There is a need in the art for a system and method that addresses the shortcomings discussed above.SUMMARY

[0005] Systems and methods for swapping electric batteries in electric vehicles are disclosed herein. The systems and methods allow a battery assembly (including one or more battery packs and a corresponding housing) to be raised and lowered using actuators that are disposed onboard of the battery assembly in order to mount and dismount the battery assembly from an electric vehicle.

[0006] In one aspect, a battery assembly for use with an electric vehicle includes a battery cage configured to hold one or more battery packs. The battery assembly also includes a set of actuating members. The set of actuating members is configured to extend from, and retract into, a bottom portion of the battery cage.

[0007] In one aspect, the battery assembly is configured to be mounted to and dismounted from the electric vehicle.

[0008] In one aspect, extending the set of actuating members lifts the battery assembly.

[0009] In one aspect, retracting the set of actuating members lowers the battery assembly.

[0010] In one aspect, at least one actuating member of the set of actuating members is fully retractable within the battery cage.

[0011] In one aspect, the set of actuating members includes at least three actuating members.

[0012] In one aspect, the set of actuating members includes four actuating members, and each actuating member may be located in one of four corners of the battery cage.

[0013] In one aspect, the set of actuating members is electrically powered, and the set of actuating members may be powered by the one or more battery packs retained in the battery cage.

[0014] In one aspect, the battery assembly includes a control system connected to each actuating member of the set of actuating members, where the control system is configured to control the extension and retraction of each actuating member of the set of actuating members.

[0015] In one aspect, the control system is configured to adjust the extension or retraction of one or more of the set of actuating members based on information received from at least one sensor.

[0016] In one aspect, the at least one sensor comprises a level detecting sensor for detecting leveling information for the battery cage.

[0017] In one aspect, the at least one sensor comprises at least one force detecting sensor associated with at least one actuating member of the set of actuating members.

[0018] In one aspect, the battery cage further includes a mounting portion configured to engage with an engagement portion of the electric vehicle.

[0019] In one aspect, the mounting portion includes at least one horizontal mounting bar.

[0020] In one aspect, the mounting portion includes an upper horizontal mounting bar and a lower horizontal mounting bar.

[0021] In one aspect, an electric vehicle system includes an electric vehicle and a battery assembly. The electric vehicle includes an electric motor, a frame, and an engagement portion extending from the frame. The battery assembly includes a battery cage configured to hold one or more battery packs, a mounting portion configured to engage with the engagement portion of the electric vehicle, and a set of actuating members, where the set of actuating members is configured to extend from, and retract into, a bottom portion of the battery cage. The set of actuating members is operable to lift the battery assembly until the mounting portion of the battery cage is disengaged from the engagement portion of the electric vehicle when the battery assembly is dismounted from the electric vehicle. The set of actuating members is operable to lower the battery assembly until the mounting portion of the battery cage is engaged with the engagement portion of the electric vehicle when the battery assembly is mounted to the electric vehicle.

[0022] In one aspect, the engagement portion includes at least one hook configured to receive the mounting portion.

[0023] In one aspect, the mounting portion includes at least one mounting bar configured to fit into, and be supported by, the at least one hook.

[0024] In one aspect, the set of actuating members is powered by the one or more battery packs.

[0025] In one aspect, a method of replacing batteries in an electric vehicle includes actuating a set of actuating members on a battery assembly to raise the battery assembly until a mounting portion of the battery assembly is disposed above an engagement portion of the electric vehicle and moving the electric vehicle relative to the battery assembly.

[0026] In one aspect, the method further includes moving the electric vehicle closer to the battery assembly and retracting the set of actuating members to load the battery assembly onto the electric vehicle.

[0027] In one aspect, the mounting portion includes a mounting bar, wherein the engagement portion includes a hook, and wherein retracting the set of actuating members lowers the mounting bar into the hook.

[0028] In one aspect, the method further includes extending the set of actuating members to unload the battery assembly from the electric vehicle and moving the electric vehicle further from the battery assembly.

[0029] In one aspect, the mounting portion includes a mounting bar, the engagement portion includes a hook, and actuating the set of actuating members comprises raising the mounting bar out of the hook.

[0030] Other systems, methods, features, and advantages of the disclosure will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description and this summary, be within the scope of the disclosure, and be protected by the following claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The disclosure can be better understood with reference to the following figures and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the disclosure. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.

[0032] FIG. 1 is a schematic view of an electric vehicle and an associated battery assembly, according to an embodiment.

[0033] FIG. 2 is a schematic view of an electric vehicle with an associated battery assembly dismounted from the electric vehicle, according to an embodiment.

[0034] FIG. 3 is a schematic view of a dual electric powertrain system for an electric vehicle, according to an embodiment.

[0035] FIGS. 4-6 are schematic views of a battery cage of a battery assembly, according to an embodiment.

[0036] FIGS. 7 is a schematic view of a battery cage in a lowered position, according to an embodiment.

[0037] FIG. 8 is a schematic view of a battery cage in a raised position, according to an embodiment.

[0038] FIGS. 9-15 are schematic views of a process for dismounting a battery assembly from an electric vehicle so that the battery assembly can be interchanged with another battery assembly, according to an embodiment.

[0039] FIG. 16 is a schematic view of various electrical components associated with a battery assembly, according to an embodiment.

[0040] FIG. 17 is a schematic view of another embodiment of a configuration for mounting a battery assembly to an electric vehicle.DETAILED DESCRIPTION

[0041] For electric vehicles it is desirable to have a system that can efficiently swap out discharged batteries with fully charged batteries so that vehicles are not idle for long periods as they wait for recharging. Some systems for swapping batteries in an electric vehicle may require substantial infrastructure. Because batteries for electric vehicles tend to be large and heavy, systems for swapping batteries might include cranes, forklifts, loading ramps, palettes, or other components for lifting, lowering, and transporting batteries to and from the vehicle. Because space is highly confined in a mine (e.g., in underground shafts), it is desirable to have a battery swapping system that limits the amount of infrastructure required. Some embodiments may utilize a so-called “zero-infrastructure” battery swap system. For such a zero-infrastructure system, all that is needed is “space and dirt” to unload discharged batteries and reload fully charged batteries.

[0042] The embodiments provide systems and methods for swapping batteries in electric vehicles by utilizing lifting mechanisms integrated into the battery cage (that is, the battery housing). More specifically, the embodiments provide a battery assembly with electrically powered actuators (for example, electric cylinders) that may be used to lift the battery assembly onto, or off of, a corresponding portion of a vehicle, such as a set of hooks that may engage portions of the battery cage.

[0043] By using a battery assembly with a self-contained lifting mechanism, the embodiments may facilitate a simpler design for an electric vehicle by eliminating the need for a complicated and expensive lifting system that is attached to the vehicle frame.

[0044] FIGS. 1 and 2 present schematic views of an electric vehicle 100 and an associated battery assembly 102, according to an embodiment. In the configuration shown in FIG. 1 , battery assembly 102 is mounted to electric vehicle 100. In the configuration shown in FIG. 2, battery assembly 102 is dismounted from electric vehicle 100.

[0045] In this exemplary embodiment, electric vehicle 100 may be a load haul dump (LHD) vehicle commonly used in underground mines. Electricvehicle 100 may also include a propulsion system comprising one or more electric motors (shown in FIG. 3) that are powered by one or more batteries.

[0046] Still referring to FIGS. 1-2, electric vehicle 100 may include a frame 101 including front frame portion 105 and a rear frame portion 107. In addition, electric vehicle 100 may include a set of wheels, including a pair of front wheels 122 mounted to the front frame portion 105 of electric vehicle 100, and a pair of rear wheels 124 mounted to the rear frame portion 107 of electric vehicle 100.

[0047] As shown in FIGS. 1-2, electric vehicle 100 may include an operator cockpit or cab 126. As also shown in FIGS. 1-2, electric vehicle 100 may include a work implement, such as a bucket 128 connected to front frame portion 105 and configured to receive a payload.

[0048] While the present embodiment comprises an LHD vehicle, it may be appreciated that the principles described herein may be used with various kinds of electric vehicles. For example, the exemplary battery swapping system could also be used with hauling and / or dump trucks.

[0049] Embodiments may incorporate one or more batteries to power the one or more motors of the electric vehicle. As used herein, the term “battery pack” generally refers to multiple battery modules in a heavy-duty pack housing. Each module is comprised of multiple battery cells. In this way, a battery pack also refers to a collection of individual battery cells. The battery cells, and therefore modules, may be functionally interconnected together.

[0050] In different embodiments, a battery pack could incorporate any suitable kind of battery cell. Examples of battery cells include capacitors, ultracapacitors, and electrochemical cells. Examples of electrochemical cells include primary (e.g., single use) and secondary (e.g., rechargeable). Examples of secondary electrochemical cells include lead-acid, valve regulated lead-acid (VRLA), gel, absorbed glass mat (AGM), nickel-cadmium (NiCd), nickel-zinc (NiZn), nickel metal hydride (NiMH), lithium-ion (Li-ion), and the like. A battery cell may have various voltage levels. In particular, in some cases two different battery cells in a battery pack could have different voltage levels. Similarly, the battery cell may have various energy capacitylevels. In particular, in some cases, two different battery cells in a battery pack could have different capacity levels.

[0051] In some cases, it may be desirable to use multiple battery packs. As used herein, the term “battery pack assembly”, or simply “battery assembly” refers to one or more battery packs along with a suitable housing. In some embodiments, a battery assembly comprises multiple battery packs as well as a housing for holding the separate battery packs together.

[0052] In the example of FIGS. 1 -2, battery assembly 102 comprises a battery cage 104. Battery cage 104 comprises a housing for one or more battery packs. Battery cage 104 may retain and protect first battery pack 110 and second battery pack 112 (shown in phantom in FIGS. 1 and 2). To this end, battery cage 104 may be sized and dimensioned to receive each of first battery pack 110 and second battery pack 112.

[0053] FIG. 3 is a schematic illustration of a dual motor electric power train system according to an exemplary embodiment intended to show how the exemplary battery packs may power electric vehicle 100. As shown in FIG. 3, an electric propulsion system 300 may include electric power source 135, including first battery pack 110 and second battery pack 112, as well as a tramming battery 305. In addition, electric propulsion system 300 may include a first electric motor 310 configured to deliver power to front wheels 122. Further, electric propulsion system 300 may include a second electric motor 315 configured to deliver power to rear wheels 124. In some embodiments, the combined output of first battery pack 110 and second battery pack 112 may be used to power first motor 310 and / or second motor 315. In some embodiments, first battery pack 110 may be configured to deliver power to first motor 310, and second battery pack 112 may be configured to deliver power to second motor 315.

[0054] As discussed in further detail below, battery assembly 102 may be removably attached to vehicle 100. As used herein, the term “removably attached” refers to two components that are joined together but that can be separated without destroying one or the other component. That is, the components can be non-destructively detached from one another. Exemplary modalities of “removable attachment” include connections made usingremoveable fasteners, latches, locks, hooks, magnetic connections as well as other kinds of connections.FIGS. 4-5 are schematic views of battery cage 104. For purposes of illustration, battery pack 110 and battery pack 112 are not shown in FIGS. 4-5. Moreover, corresponding components of electric vehicle 100 are shown as connected to battery cage 104. Specifically, provisions of electric vehicle 100 associated with mounting battery cage 104 are shown and indicated with shading.

[0055] Referring to FIGS. 4-5, battery cage 104 includes an outward end portion 210, a vehicle engaging end portion 212, a first side portion 214 and a second side portion 216. Battery cage 104 may also include a top portion 218 and a bottom portion 220. These various portions are sized and shaped to accommodate battery packs. In particular, outward end portion 210, vehicle engaging end portion 212, first side portion 214 and second side portion 216 along with bottom portion 220 are structural portions that bound an interior cavity 230. Moreover, in some embodiments, an interior dividing portion 232 further divides interior cavity 230 into a first sub-cavity 234 and a second sub-cavity 236 wherein each sub-cavity is configured to receive one battery pack. In this embodiment, bottom portion 220 comprises a bottom structural portion to support the battery packs below. Top portion 218 may be an open portion of battery cage 104 that facilitates easy access to interior cavity 230. In some cases, top portion 218 may be associated with a separate panel or cover that encloses the battery packs. For example, in FIG. 1 , top portion 218 is associated with a top cover 130. In other embodiments, other structural components could be used along top portion 218 as well. In some cases, a top portion could comprise a hinged panel that may be opened to provide access to interior cavity 230. In some cases, a top portion could comprise a removable structural panel that may be suitably fastened to adjacent portions of battery cage 104.

[0056] In some embodiments, battery cage 104 may also be sized and shaped to provide an extension of the vehicle’s frame when battery cage 104 is mounted to the vehicle. For example, in some embodiments, first side portion 214, second side portion 216 and bottom portion 220 may beapproximately coincident with corresponding portions of frame 101 of vehicle 100 (see FIG. 1 ) when battery cage 104 is mounted to electric vehicle 100.

[0057] Battery cage 104 may include provisions to facilitate mounting and dismounting. Some embodiments may include one or more horizontal bars that are configured to facilitate mounting. Some embodiments may include one or more vertical bars that are configured to facilitate mounting. Some embodiments may include a combination of horizontal and vertical bars to facilitate mounting.

[0058] As best seen in FIG. 7, battery cage 104 includes a set of horizontal mounting bars, including an upper mounting bar 242 and a lower mounting bar 244.

[0059] Each horizontal mounting bar may be retained by a corresponding engaging portion of a vehicle. For example, as shown in FIG. 2, vehicle 100 includes hooks 140 to retain the mounting bars of battery cage 104. It may be appreciated that the term “hook” as used herein is not intended to be limited to a particular size or geometry. As used herein a hook refers to any piece of material (e.g., metal) that is curved or bent for the purpose of holding, catching, or otherwise engaging other elements. In the exemplary embodiment, electric vehicle 100 includes four hooks, with two hooks used to retain upper mounting bar 242 and two hooks used to retain lower mounting bar 244. In the exemplary embodiment, hooks 140 include a set of upper hooks 142 (shown in FIGS. 2 and 4) for retaining upper mounting bar 242 (shown in FIG. 4) and a set of lower hooks 144 (shown in FIG. 2) for retaining lower mounting bar 244 (shown in FIGS. 4 and 5). To provide enhanced stability, set of upper hooks 142 comprises two hooks that are spaced apart laterally and set of lower hooks 144 also comprises two hooks that are spaced apart laterally. Using pairs of laterally spaced hooks may reduce the tendency of the mounting bars to rock or tip in a lateral direction relative to the hooks.

[0060] In some embodiments, electric vehicle 100 also includes locking elements to help secure upper mounting bar 242 and lower mounting bar 244 in place. Locking elements may comprise any suitable components for locking or retaining mounting bars in place including latches. In some embodiments, locking elements may comprise downward facing hooks thatare lowered over mounting bars once the mounting bars are properly engaged with their corresponding upward facing hooks. For example, as seen in FIG.2, vehicle 100 includes a set of locking elements 150 that may engage upper mounting bar 242 and lower mounting bar 244. In the exemplary embodiment, set of locking elements 150 may be raised and lowered while hooks 140 remain fixed in place relative to vehicle 100. Specifically, set of locking elements 150 may be lowered to help retain the upper and lower mounting bars once they are received within hooks 140. Likewise, set of locking elements 150 may also be raised to allow the upper and lower mounting bars to be disengaged from hooks 140.

[0061] In different embodiments, materials for battery cage 104 may vary. In some embodiments, battery cage 104 may be constructed of a material including a metal or metal alloy. In some embodiments, battery cage 104 may be constructed of a similar material to the material used in the frame of vehicle 100.

[0062] While the embodiments of FIGS. 1 -5 depict a configuration in which mounting bars are disposed on a battery assembly and engage hooks disposed on a frame of the vehicle, in other embodiments other configurations could be used. In another embodiment, for example, a battery assembly could include hooks that engage with mounting bars attached to the frame of the vehicle. For example, FIG. 17 is a schematic side view of a configuration where a battery assembly 1702 includes downward facing hooks 1703 that are configured to hook over mounting bars 1704 of vehicle frame 1706. As with earlier embodiments, battery assembly 1702 may be raised to a sufficient height (using actuating members 1750) so that hooks 1703 may be engaged / disengaged from mounting bars 1704.

[0063] Embodiments may include provisions for lifting a battery assembly. In some embodiments, battery assembly 102 includes an integrated lifting system that may raise and lower the battery assembly (including the battery cage and the one or more battery packs) with respect to a ground surface. In some embodiments, a lifting system includes one or more actuators that are arranged within the battery cage, and which are configured to extend and retract with respect to the battery cage. Moreparticularly, the actuators may extend from, and retract into, a bottom portion of the battery cage.

[0064] As best seen in FIG. 6, battery assembly 102 may include a set of actuating members 250. The set of actuating members 250 may comprise a first actuating member 251 , a second actuating member 252, a third actuating member 253, and a fourth actuating member 254.

[0065] In different embodiments, different kinds of actuating members may be used, including any actuating members suitable for the specific demands of raising and lowering a battery assembly. Examples include hydraulic actuators, known for their high force capabilities and precision, and electric linear actuators, which offer clean, efficient, and quiet operation. Pneumatic actuators may also be utilized for their simplicity and rapid response times, while screw jacks might be employed for their mechanical advantage and robustness. The selection of actuator type may be customized based on the required extension-retraction speed, force, durability, and environmental resistance. In some embodiments, electrical actuators (or electrical cylinders) are used and incorporate screw / threaded components to facilitate enhanced precision of the extension and retraction of the actuators.

[0066] In some embodiments, each of the set of actuating members 250 may comprise a linear actuator. Each actuating member may comprise an actuating body and a piston or other portion that extends from the actuating body. In some embodiments, actuating members are electrically powered and utilize a motor, gearbox and screw to power extension and retraction of the piston. Some embodiments may use a telescoping design, including multiple stage actuators. For example, the shape of a battery cage may require actuating members to extend to different heights, depending on their position along the battery cage. This may be accomplished using actuators of different sizes or using multistage actuators.

[0067] Each actuating member may be configured with an outward end (also referred to as an extending end), which may extend away from a bottom portion of a battery cage, and an inward end. In some cases, the inward ends may be fixed in place with respect to the battery cage and maygenerally reside between a top portion and a bottom portion of the battery cage. In other cases, the inward ends may also move relative to the battery cage, while another intermediate portion of the actuating members stays fixed relative to some portion of the battery cage.

[0068] As shown in FIG. 6, first actuating member 251 comprises a stationary component 402 and a moveable component 404. Stationary component 402 may comprise a rod or similar structure that has an inward most end 412 fixed to battery cage 104. Moveable component 404 may move relative to both stationary component 402 and battery cage 104. In particular, moveable component 404 moves up and down the length of stationary component 402 as moveable component 404 is retracted or extended, respectively.

[0069] In another embodiment, an actuating member may comprise a hydraulic cylinder with an attached moveable component or leg. In such an embodiment, a rod or piston of the cylinder may be fixedly attached to the moveable component so that as the rod or piston is extended / retracted relative to the cylinder the moveable component is also extended / retracted from the battery cage.

[0070] In an exemplary embodiment, moveable component 404 comprises a leg-like structure having an approximately rectangular crosssection. However, in other embodiments, any other suitable geometry could be used for a moveable component. In some embodiments, for example, a moveable component may have a circular cross-sectional shape.

[0071] Moveable component 404 includes an outward most end 410 of first actuating member 251 , while stationary component 402 includes the inward most end 412 of first actuating member 251. In the exemplary embodiment, outward most end 410 is extended and retracted from bottom portion 220 of battery cage 104, while inward most end 412 has a fixed (stationary) position adjacent top portion 218 of battery cage 104.

[0072] Moveable component 404 may also include a footing element 406. In some cases, footing element 406 is shaped to increase the contact area between outward most end 410 of first actuating member 251 and a ground surface to enhance stability. In the exemplary embodiment,footing element 406 has an approximately rectangular shape. Moreover, the cross-sectional area defined by footing element 406 may be substantially greater than the cross-sectional area of an adjacent portion of moveable component 404.

[0073] It may be appreciated that each of the other actuating members 250 may have substantially similar configurations, including a moveable component and a stationary component, as well as a footing element.

[0074] For purposes of simplicity, the actuating members 250 of the embodiments are shown as having a single moving component that moves relative to a stationary component (such as a rod or other structure). However, in other embodiments, actuating members could comprise multistage actuators with two or more moveable components that may be nested. Using multiple nested components may facilitate increased extension in some cases.

[0075] In different embodiments, the locations of one or more actuating members could vary. In some embodiments, the locations of each actuating member 250 may be selected to provide sufficient stability for raising and lowering the battery cage with respect to a ground surface. In an exemplary embodiment, each actuating member of set of actuating members 250 may be located approximately in a corresponding corner of battery cage 104. For instance, as seen in FIG. 5, first actuating member 251 is disposed in a first corner 301 of battery cage 104, second actuating member 252 is disposed in a second corner 302 of battery cage 104, third actuating member 253 is disposed in a third corner 303 of battery cage 104, and fourth actuating member 254 is disposed in a fourth corner 304 of battery cage 104. By placing each actuating member near or at a corresponding corner of battery cage 104, the exemplary design may provide sufficient stability for raising and lowering the battery cage with respect to a ground surface.

[0076] FIGS. 7-8 depict schematic views of battery cage 104 in two different positions (or configurations). Specifically, in FIG. 7, the set of actuating members 250 are retracted. In this ‘retracted’ configuration, the footing elements of second actuating member 252 and third actuatingmember 253 may be substantially flush with bottom portion 220 of battery cage 104 (see also FIG. 5) while the footing elements of first actuating member 251 and fourth actuating member 254 may slightly extend out of the bottom portion 220 of the battery cage 104 to account for the rise along the back side of bottom portion 220. In this retracted configuration, at least some of bottom portion 220 of battery cage 104 is disposed against a ground surface 501 . In particular, the region of bottom portion 220 disposed closer to vehicle engaging end portion 212 is disposed against ground surface 501 , while a region closer to outward end portion 210 is raised above ground surface 501. In FIG. 8, the set of actuating members 250 are extended. In this ‘extended’ configuration, bottom portion 220 of battery cage 104 is raised above the ground surface 501 . Moreover, all the actuating members extend outwardly from bottom portion 220 of the battery cage 104.

[0077] As discussed in further detail below, adjusting the positions (that is, the amount of extension) of the actuating members allows the lifting system to raise and lower the battery cage with respect to the ground or other surface. Moreover, raising and lowering the battery cage facilitates mounting the battery assembly to, and dismounting the battery assembly from, the vehicle frame.

[0078] In some embodiments, vehicle 100 is configured with all the provisions necessary to dismount discharged batteries and mount fully charged batteries on the ground of a mine. Such provisions may include a battery assembly with actuating members, as described above.

[0079] FIGS. 9-15 depict schematic views of a process for dismounting a battery assembly 102 from electric vehicle 100 so that battery assembly 102 can be replaced, or swapped, with another battery assembly whose battery packs are charged. In some embodiments, this process occurs within a battery swapping area of a mine so that electric vehicle 100 may continue to operate with limited down time.

[0080] Referring first to FIG. 9, battery assembly 102 is mounted to electric vehicle 100. For purposes of illustration, components of vehicle 100 and battery assembly 102 are shown schematically. These include hooks 140 further comprised of a set of upper hooks 142 and a set of lower hooks 144,which extend from, and are rigidly fixed to, vehicle 100. Moreover, battery assembly 102 includes cage 104, which further comprises upper mounting bar 242 and lower mounting bar 244. Using this configuration, battery assembly 102 is secured to frame 101 of vehicle 100 using hooks 140. For simplicity, locking elements are not shown in FIGS. 9-15. However, it may be appreciated that locking elements may be used to further secure the mounting bars of the battery cage in place within hooks 140.

[0081] In the configuration shown in FIG. 9, some actuating members may be partially (but not fully) extended from battery cage 104 while the battery assembly 102 is mounted to vehicle 100. In some cases, for example, first actuating member 251 and fourth actuating member 254 may partially extend by a distance 705 from bottom portion 220 even when the system is in a fully retracted configuration, thereby ensuring that battery assembly 102 will be level if placed on a ground surface.

[0082] In other embodiments, all actuating members may be fully retracted within battery cage 104 whenever battery assembly 102 is mounted to electric vehicle 100.

[0083] Some embodiments may include provisions to improve stability and durability at portions of a battery cage that are raised. In some cases, outer support sleeves having a fixed extension with respect to battery cage 104 could be used with first actuating member 251 and fourth actuating member 254. For example, FIG. 9 depicts an optional outer support sleeve 709 that extends distance 705 from bottom portion 220. Distance 705 may be seen to approximately correspond to the distance that bottom portion 220 is raised along the outward end portion of battery cage 104. First actuating member 251 may move through outer support sleeve 709 as it extends and retracts, while outer support sleeve 709 maintains a fixed position. Moreover, outer support sleeve 709 may be made sufficiently rigid to bear the weight of battery cage 104 along the corresponding corner. This configuration may facilitate stability by using fixed supports for weight bearing in the retracted configuration rather than relying solely on the actuating members for weight bearing at all times while a battery assembly is on the ground. In other embodiments, no support sleeves may be used.

[0084] In still other embodiments, a bottom portion of a battery cage may be substantially flat so that all actuating members may be fully retracted into (or made flush with) the bottom portion in the retracted configuration.

[0085] In some embodiments, the process of dismounting a battery assembly begins with an operator of the vehicle or a remote operator / system indicating, using a suitable interface, that the battery assembly should be dismounted. This generates a signal that may be transmitted to components of the battery assembly, as described in further detail below with respect to FIG. 16.

[0086] Once any corresponding locking elements have been raised or otherwise disengaged from the mounting bars, the process of dismounting battery assembly 102 proceeds with extending the set of actuating members 250 from battery cage 104. In a configuration shown in FIG. 10, the actuating members 250 may be partially extended, but have not yet contacted a ground surface 701 .

[0087] As the set of actuating members 250 continues to extend, they make initial contact with ground surface 701 , as shown in FIG. 11 . As the set of actuating members 250 continues to extend, they provide sufficient force to lift battery cage 104 up and off of set of upper hooks 142 and set of lower hooks 144, as shown in FIG. 12. At this point, battery cage 104 is held above the ground surface 701 by the set of actuating members 250 alone, and does not require further support from any part of electric vehicle 100 to remain raised.

[0088] In the exemplary embodiment, lifting upper mounting bar 242 and lower mounting bar 244 above their respective hooks requires lifting battery cage 104 to at least a threshold height. This threshold height 1002 corresponds to a distance between, for instance, set of lower hooks 144 and a portion 1004 of ground surface 701 directly beneath set of lower hooks 144. Threshold height 1002 may also be characterized by a distance between set of lower hooks 144 and a bottom most portion of the vehicle wheels 1020. In other words, actuating members 250 must be extended sufficiently so that, for instance, lower mounting bar 244 is raised above threshold height 1002. A similar (upper) threshold height 1003 may be defined for set of upper hooks142 such that upper mounting bar 242 must be raised above this height. Because set of lower hooks 144 and set of upper hooks 142 are spaced vertically by a fixed distance, this same fixed offset distance may be used to determine the upper threshold height from the lower threshold height.

[0089] Once the set of actuating members 250 have been extended sufficiently to raise upper mounting bar 242 and lower mounting bar 244 above the set of upper hooks 142 and the set of lower hooks 144, respectively, electric vehicle 100 can pull away from battery assembly 102, as shown in FIG. 13.

[0090] In some embodiments, as soon as vehicle 100 is sufficiently distanced from battery cage 104, the set of actuating members 250 may be retracted to lower battery cage 104 as shown in FIG. 14. In some cases, battery cage 104 is lowered until at least some of bottom portion 220 of battery cage 104 is in contact with ground surface 701 , as shown in FIG. 15. At this point, vehicle 100 may proceed to mount a different battery assembly with charged battery packs. It may be appreciated that battery packs 110 and 112 of battery assembly 102 can be recharged using any suitable charging infrastructure and battery assembly 102 can be subsequently mounted to another electric vehicle.

[0091] The process of mounting a battery assembly may be substantially similar to the process of dismounting shown in FIG. 9-15, with some steps being performed in a reverse order. In particular, actuating members of a battery assembly may be extended until mounting bars of the battery cage are disposed above the level of hooks on the electric vehicle. The vehicle may move towards the battery assembly until the mounting bars are disposed over the hooks, at which point the actuating members may be retracted so that the mounting bars settle into the hooks on the electric vehicle.

[0092] It is contemplated that in other embodiments, rather than lifting a battery cage completely to a height where the mounting bars are raised above the corresponding hooks, the battery cage may be lifted to a sufficient height and then the height of the electric vehicle could be lowered slightly, so that the hooks (whose vertical positions are fixed with respect tothe frame of the vehicle) are lowered beneath the mounting bars. For example, in an embodiment where the electric vehicle is a truck (e.g., an articulated dump truck), the vehicle suspension system may be operated to slightly lower the frame of the vehicle with respect to a ground surface, thereby lowering the hooks until the mounting bars are fully disengaged.

[0093] The exemplary system and process described here allows an entire battery assembly (which may comprise multiple battery packs) to be dismounted from an electric vehicle, rather than removing one battery pack at a time for replacement. This may facilitate quicker reloading and allow for a more efficient charging infrastructure.

[0094] Although not shown in FIGS. 9-15, the exemplary process may further include steps of disconnecting (or connecting) electrical connections, as well as possibly other connections (such as fluid connections that allow cooling fluid to flow between a battery assembly and an electric vehicle).

[0095] In an exemplary embodiment, each battery pack of battery assembly 102 may be disconnected from one or more electrical circuits of vehicle 100. Such electrical circuits can be circuits that direct power between one or more batteries and one or more motors. In one embodiment, each battery pack is connected by at least one cable to one or more electrical circuits. Thus, electrically disconnecting each battery pack requires disconnecting one or more cables.

[0096] In an exemplary embodiment, each battery pack may also be connected to hoses that run fluids between the batteries and vehicle 100. For example, some embodiments may run cooling fluid for cooling through the batteries. In such embodiments, the hoses connecting to one or more fluid ports on the battery packs may also be disconnected prior to dismounting a battery assembly. Alternatively, in other embodiments, hoses used for fluid cooling may only be attached when the battery packs are dismounted (e.g., they may be cooled during charging).

[0097] In different embodiments, disconnecting cables and / or hoses could be done manually or automatically. In some embodiments, prior to dismounting the battery assembly, a vehicle operator may exit the vehicle andwalk over to the battery assembly. The operator may then manually disconnect electrical cables as well as fluid hoses. This could be done before or after the battery assembly has been raised for separation from the electric vehicle. Alternatively, it may be understood that in some other embodiments electrical connections (and / or fluid connections) could be automatically disconnected.

[0098] In some embodiments, after a battery assembly has been dismounted and lowered to the ground again, an operator may have the option to plug in one or both battery packs for recharging. For example, in one embodiment, one or more long charging cables may be found in the vicinity of the location where the battery assembly is dismounted. The charging cables could be connected to a power source that is located elsewhere in the mine (or even outside of the mine).

[0099] In another embodiment, battery swapping may occur adjacent one or more charging stations. In such embodiments, a battery assembly may be dismounted at a location directly adjacent to a charging station. In still other embodiments, batteries may not be recharged at the swapping site, but may be moved to another location for charging. For example, in some embodiments, a crew of workers could collect discharged batteries throughout the mine and bring them to another location within (or outside) the mine where charging infrastructure is provided. This same crew could then deliver recently charged batteries to locations throughout the mine where it is anticipated that LHD vehicles, haul trucks, or other electric mining vehicles may be operating.

[0100] FIG. 16 is a schematic view of various electrical components associated with a battery assembly 102, according to an embodiment. Battery assembly 102 may include provisions for powering a vehicle. In the exemplary embodiment, battery assembly 102 includes a first battery pack 1302 and a second battery pack 1304. In other embodiments, a battery assembly could include any other number of battery packs, including, for example, three or more battery packs.

[0101] Battery assembly 102 may include provisions for extending and retracting actuating members. Each actuating member 250 may comprisea mechanical component that may be extended and retracted in response to operation of an associated motor, or other source of actuation. In the exemplary embodiment, battery assembly 102 includes multiple electrically powered actuator motors, including first actuator motor 1320, second actuator motor 1322, third actuator motor 1324, and fourth actuator motor 1326. Each actuator motor may be used to extend and retract a corresponding actuating member of the battery assembly. In some cases, the actuating motors are integrated into the actuating members. In some embodiments, the actuating motors facilitate turning a screw or other threaded component to drive one of the actuating components along the threaded component, thereby extending or retracting the driven component.

[0102] In underground mining, ground surfaces may be sloped or otherwise uneven. Battery assembly 102 may include provisions for maintaining stability of a battery assembly as a battery cage is raised and lowered, even when a ground surface is not level and / or is uneven. In an exemplary embodiment, battery assembly 102 may be equipped with one or more sensors that facilitate mounting / dismounting and storing the battery in a way that facilitates stability.

[0103] In some embodiments, a battery assembly includes force sensors 1330. Force sensors 1330 may be used to detect when the footing element of each actuator has made contact with a ground surface during the dismounting process. In some cases, each actuating member includes an associated force sensor. In some cases, each actuating member includes a force sensor disposed on or around the corresponding footing element of the actuating member.

[0104] In some embodiments, a battery assembly includes sensors for detecting whether the battery assembly is level. In different embodiments, any suitable sensors for determining leveling information may be determined including tilt sensors, gyroscopes, accelerometers, and / or any suitable combination of these sensors. Suitable tilt sensors may include one-axis or two-axis digital inclinometers, inclinometers with gyroscopes, or other suitable tilt sensors known in the art. In an exemplary embodiment, battery assembly102 comprises one or more leveling sensors 1332, comprised of one or more of a gyroscope, and / or an accelerometer.

[0105] In some embodiments, battery assembly 102 includes provisions to adjust the operation of one or more actuating members in response to information from one or more leveling sensors. For example, if a ground surface is sloped so that the front end of a battery cage tilts down when the cage is disposed on the ground, the actuating members may be controlled so that the actuating members at the front end extend further as the cage is raised, thereby helping to level the battery cage in its fully raised position so as to prevent the cage from tipping over in this position.

[0106] In an exemplary embodiment, battery assembly 102 includes a control system 1340, which coordinates the operation of each actuating member. Specifically, control system 1340 controls the actuator motors to raise and lower the battery cage. Moreover, control system 1340 may coordinate the raising and lowering of the battery cage such that the battery cage remains sufficiently level (or otherwise stable) at all times.

[0107] In one exemplary mode of operation, during the dismounting process, control system 1340 operates the corresponding motors to extend each actuating member until information is received from force sensors 1330 indicating that each actuating member has made contact with a ground surface. At this point, control system 1340 monitors information from leveling sensors 1332 and controls the extension of each actuating member in a way that keeps battery assembly 102 level as it is raised above the threshold height to dismount battery cage 104. Thus, for example, control system 1340 may receive information from leveling sensors 1332 and send control signals to each of the actuator motors to ensure the battery cage is level throughout the lifting or lowering process. In particular, control system 1340 may operate the actuator motors independently so that some actuating members extend (or retract) more relative to other actuating members in order to keep the battery cage level or otherwise stable.

[0108] In some embodiments, control system 1340 may include one or more communication systems 1350. Communication systems 1350 may comprise networking hardware configured to interface with other nodes of anetwork, such as a LAN, WLAN, or other networks. In some cases, communications between components may be made via the Internet, a cellular network, WIFI, or other suitable communications network. Any suitable communication platforms and / or protocols may be utilized for communication between one component and other components of the system. Since the various sources of information may each have their own platform and / or protocol, the system may be configured to interface with each platform and / or protocol to receive the data.

[0109] In some embodiments, communication systems 1350 of control system 1340 communicates with one or more vehicle communication systems onboard of electric vehicle 100. In some embodiments, communication systems 1350 receive signals and / or messages from vehicle control systems 1360 to initiate a mounting and / or dismounting process. Vehicle control systems 1360 may be operated at a vehicle or at a remote system. For example, when an operator of a vehicle is ready to dismount the current battery assembly, the operator may press a button on a control panel of the vehicle which transmits a message via vehicle control systems 1360 to communication systems 1350. Upon detecting this message, control system 1340 may begin initiating the dismounting process by extending the actuating members. A similar process may be used during the mounting process to instruct the battery assembly to raise to a sufficient height for mounting. Communication between the battery communication systems 1350 and the vehicle control systems 1360 may facilitate coordination between the vehicle and the battery assembly during mounting or dismounting. For example, communication may be used to ensure that any locking members are released on the vehicle side before the battery assembly begins to lift off of the vehicle’s hooks during the dismounting process. Communication may also be used to ensure the battery assembly does not lower to the ground until after a vehicle has pulled away during the dismounting process.

[0110] An exemplary set of operations during a dismounting process may occur as follows. First, an operator (human or autonomous) sends a command to begin the dismounting process. Vehicle control systems 1360 may then unlock any locking elements on the vehicle side used to helpretain the battery assembly. Once the locking elements are released, vehicle control systems 1360 send a message to control system 1340 (via communications systems 1350) to begin extending the actuating members until the battery assembly is raised above a threshold height. In some cases, once the battery assembly is raised to a sufficient height, control system 1340 sends a message back to vehicle control systems 1360 to confirm it is permitted for the vehicle to move away from the battery assembly. In some cases, once the vehicle has moved sufficiently far from the battery assembly, vehicle control systems 1360 send a message to control system 1340 to confirm the battery assembly can now be lowered to the ground. A similar set of operations could be performed to coordinate activity between a vehicle and a battery assembly during the process of mounting the battery assembly.

[0111] Embodiments may use different methods of powering actuating members to lift a battery assembly. In some embodiments, power for actuation may be drawn from one or more battery packs in a battery assembly. In such cases, control system 1340 may monitor battery charge levels and provide sufficient information to an operator or other control systems that ensures sufficient power remains in the one or more battery packs to power dismounting the battery assembly by extending the actuating members and then safely retracting them once the battery assembly has been dismounted. In another embodiment, power could be provided using a tethered connection to a battery onboard the electric vehicle, such as a tramming battery that may power the vehicle for short durations while it is not connected to a battery assembly. In such cases, an operator may take care to ensure that the battery assembly remains tethered to the vehicle-side battery until the dismounting process has been completed.

[0112] The control system described herein may be implemented using any suitable computing system, including one or more processors and suitable memory for storing instructions that may be executed by the one or more processors.

[0113] The processes and methods of the embodiments described in this detailed description and shown in the figures can be implemented using any kind of computing system having one or more central processing units(CPUs) and / or graphics processing units (GPUs). The processes and methods of the embodiments could also be implemented using special purpose circuitry such as an application specific integrated circuit (ASIC). The processes and methods of the embodiments may also be implemented on computing systems including read only memory (ROM) and / or random access memory (RAM), which may be connected to one or more processing units. Examples of computing systems and devices include, but are not limited to: servers, cellular phones, smart phones, tablet computers, notebook computers, e-book readers, laptop or desktop computers, all-in-one computers, as well as various kinds of digital media players.

[0114] The processes and methods of the embodiments can be stored as instructions and / or data on non-transitory computer-readable media. The non-transitory computer readable medium may include any suitable computer readable medium, such as a memory, such as RAM, ROM, flash memory, or any other type of memory known in the art.

[0115] While this specification contains many specifics, these should not be construed as limitations on the scope of the disclosure or of what may be claimed, but rather as descriptions of features specific to particular implementations. Certain features that are described in this specification in the context of separate implementations may also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation may also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination may in some examples be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a sub-combination.

[0116] Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may beadvantageous. Moreover, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described program components and systems may generally be integrated together in a single software product or packaged into multiple software products.

[0117] While various embodiments of the disclosure have been described, the description is intended to be exemplary, rather than limiting, and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the disclosure. Accordingly, the disclosure is not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.

Claims

CLAIMS1 . A battery assembly for use with an electric vehicle, the battery assembly comprising: a battery cage configured to hold one or more battery packs; and a set of actuating members; wherein the set of actuating members are configured to extend from, and retract into, a bottom portion of the battery cage.

2. The battery assembly according to claim 1 , wherein the battery assembly is configured to be mounted to and dismounted from the electric vehicle.

3. The battery assembly according to claim 1 or 2, wherein extending the set of actuating members lifts the battery assembly.

4. The battery assembly according to any one of claims 1 to 3, wherein retracting the set of actuating members lowers the battery assembly.

5. The battery assembly according to any one of claims 1 to 4, wherein at least one actuating member of the set of actuating members is fully retractable within the battery cage.

6. The battery assembly according to any one of claims 1 to 5, wherein the set of actuating members includes at least three actuating members.

7. The battery assembly according to any one of claims 1 to 5, wherein the set of actuating members includes four actuating members.

8. The battery assembly according to claim 7, wherein each actuating member is located in one of four comers of the battery cage.

9. The battery assembly according to any one of claims 1 to 8, wherein the set of actuating members is electrically powered.

10. The battery assembly according to claim 9, wherein the set of actuating members is electrically powered by the one or more battery packs retained in the battery cage.11 . The battery assembly according to any one of claims 1 to 10, further including a control system connected to each actuating member of the set of actuating members, wherein the control system is configured to control the extension and retraction of each actuating member of the set of actuating members.

12. The battery assembly according to claim 11 , wherein the control system is configured to adjust the extension or retraction of one or more actuating members of the set of actuating members based on information received from at least one sensor.

13. The battery assembly according to claim 12, wherein the at least one sensor includes a level detecting sensor for detecting leveling information for the battery cage.

14. The battery assembly according to claim 12, wherein the at least one sensor includes at least one force detecting sensor associated with at least one actuating member of the set of actuating members.

15. The battery assembly according to any one of claims 1 to 14, wherein the battery cage further includes a mounting portion configured to engage with an engagement portion of the electric vehicle.

16. The battery assembly according to claim 15, wherein the mounting portion includes at least one horizontal mounting bar.

17. The battery assembly according to claim 15, wherein the mounting portion includes an upper horizontal mounting bar and a lower horizontal mounting bar.

18. An electric vehicle system, comprising: an electric vehicle, the electric vehicle comprising: an electric motor; a frame; and an engagement portion extending from the frame; and a battery assembly, the battery assembly comprising: a battery cage configured to hold one or more battery packs; a mounting portion configured to engage with the engagement portion of the electric vehicle; and a set of actuating members, wherein the set of actuating members is configured to extend from, and retract into, a bottom portion of the battery cage; wherein the set of actuating members is operable to lift the battery assembly until the mounting portion of the battery cage is disengaged from the engagement portion of the electric vehicle when the battery assembly is dismounted from the electric vehicle; and wherein the set of actuating members is operable to lower the battery assembly until the mounting portion of the battery cage is engaged with the engagement portion of the electric vehicle when the battery assembly is mounted to the electric vehicle.

19. The electric vehicle system according to claim 18, wherein the engagement portion comprises at least one hook configured to receive the mounting portion.

20. The electric vehicle according to claim 19, wherein the mounting portion comprises at least one mounting bar configured to fit into, and be supported by, the at least one hook.21 . The electric vehicle system according to any one of claims 18 to 20, wherein the set of actuating members is powered by the one or more battery packs.

22. A method of replacing batteries in an electric vehicle, comprising: actuating a set of actuating members on a battery assembly to raise the battery assembly until a mounting portion of the battery assembly is disposed above an engagement portion of the electric vehicle; and moving the electric vehicle relative to the battery assembly.

23. The method according to claim 22, wherein the method further includes moving the electric vehicle closer to the battery assembly and retracting the set of actuating members to load the battery assembly onto the electric vehicle.

24. The method according to claim 23, wherein the mounting portion comprises a mounting bar, wherein the engagement portion comprises a hook, and wherein retracting the set of actuating members lowers the mounting bar into the hook.

25. The method according to claim 22, wherein the method further includes extending the set of actuating members to unload the battery assembly from the electric vehicle and moving the electric vehicle further from the battery assembly.

26. The method according to claim 25, wherein the mounting portion comprises a mounting bar, wherein the engagement portion comprises a hook, and wherein actuating the set of actuating members comprises raising the mounting bar out of the hook.

27. The method according to any one of claims 22 to 26, wherein the method further includes receiving information from one or more levelingsensors and operating the set of actuating members in response to the information from the one or more leveling sensors.

Images