An automated cassette handling system

Abstract

An automated cassette handling system Embodiments herein disclose a fully automated cassette handling system within a charging and interchange station, which ensure swift and safe cassette handling, mitigating the risks associated with manual or semi-automatic processes, while optimizing efficiency and minimizing the potential for accidents or damage, thus facilitating seamless operations in the realm of heavy electric vehicle infrastructure. Embodiments herein disclose an automated cassette handling system that streamlines the cassette interchange process, reducing downtime for vehicles and improving overall operational efficiency. Embodiments herein disclose an automated cassette handling system that is robust, dependable, and capable of performing consistently under varying operational conditions. Embodiments herein disclose an automated cassette handling system that is cost-effective and safe. Embodiments herein disclose an automated cassette handling system that is easy to maintain

Description

CROSS-REFERENCE TO RELATED APPLICATIONThis application is based on and derives the benefit of Indian Provisional Application IN202441065100, the contents of which are incorporated herein by reference.TECHNICAL FIELD

[0001] Embodiments disclosed herein relate to automated cassette handling systems, and more particularly to an automated cassette handling system for a charging and interchange station.BACKGROUND

[0002] In the contemporary era, the global transition towards electric vehicles (EVs) is gaining momentum, driven by the numerous advantages they offer over traditional internal combustion engine vehicles. Electric vehicles contribute significantly to reducing greenhouse gas emissions, lowering operational costs, and promoting energy independence by utilizing renewable energy sources. Despite these benefits, conventional electric vehicles still face notable challenges, particularly in the form of prolonged charging times and limited driving range. These drawbacks can hinder widespread adoption, especially in applications demanding high availability and long-distance travel. To address such limitations, the concept of cassette interchange, often referred to as battery interchange has emerged as a promising solution. This approach allows for quick replacement of depleted storage devices with fully charged ones, offering a viable alternative not only for passenger cars but also for heavy-duty vehicles like trucks and buses.

[0003] However, the implementation of electrical energy storage device interchange in heavy-duty vehicles introduces its own set of challenges. The cassettes used in these vehicles are significantly larger, bulkier, and heavier than those used in passenger vehicles, reflecting the greater energy demands of commercial and industrial transport. The immense size and mass of these devices make manual handling virtually impossible and unsafe, as it would require extraordinary physical effort and expose workers to considerable risk. Even semi-automatic handling solutions, such as stackers or hoists, are not straightforward because they demand skilled operators to manoeuvre the equipment efficiently and safely. This dependency on trained personnel not only increases operational complexity but also raises labour costs and slows down the interchange process.

[0004] Moreover, the risks associated with manual or semi-automatic handling of heavy cassettes extend beyond operational inefficiency. Improper handling can result in mechanical damage to the storage devices, which could compromise their performance or render them unusable. Additionally, there is a heightened risk of injury to operators due to the weight and unwieldy nature of the devices, as well as potential damage to the vehicles themselves during the interchange process. Such hazards highlight the critical need for robust, automated, and safe handling mechanisms specifically designed to accommodate the unique challenges posed by heavy-duty cassettes, ensuring both efficiency and safety in interchange operations.

[0005] Hence, there is a need in the art for solutions which will overcome the above mentioned drawback(s), among others.OBJECTS

[0006] The principal object of embodiments herein is to disclose a fully automated cassette handling system within a charging and interchange station, which ensures swift and safe handling of cassettes, mitigating the risks associated with manual or semi-automatic processes, while optimizing efficiency and minimizing the potential for accidents or damage, thus facilitating seamless operations.

[0007] Another object of embodiments herein is to disclose an automated cassette handling system that streamlines the cassette interchange process, reducing downtime for heavy electric vehicles and improving overall operational efficiency.

[0008] Another object of embodiments herein is to disclose an automated cassette handling system that is robust, dependable, and capable of performing consistently under varying operational conditions.

[0009] Another object of embodiments herein is to disclose an automated cassette handling system that is cost-effective and safe.

[0010] Another object of embodiments herein is to disclose an automated cassette handling system that is easy to maintain.

[0011] Another object of embodiments herein is to disclose an automated cassette handling system that minimizes the need for skilled operators, thereby simplifying operation and reducing labour costs.

[0012] Another object of embodiments herein is to disclose an automated cassette handling system that reduces the risk of damage to cassettes, vehicles, and associated handling equipment.

[0013] Another object of embodiments herein is to disclose an automated cassette handling system that enhances operator safety by eliminating the need for manual handling of heavy cassettes.

[0014] Another object of embodiments herein is to disclose an automated cassette handling system that is adaptable to accommodate varying sizes, weights, and configurations of cassettes used in heavy electric vehicles.

[0015] Another object of embodiments herein is to disclose an automated cassette handling system that enables scalability of interchange stations, allowing them to efficiently manage higher volumes of vehicles as demand increases.

[0016] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating at least one embodiment and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.SUMMARY

[0017] Embodiments herein disclose an automated cassette handling system, wherein the system comprises a horizontal movement system which can be firmly affixed to a charging and interchange station or to the ground. The horizontal movement system can have an upper mounting beam and a lower mounting beam. The horizontal movement system includes an upper guide rail mounted securely onto the upper mounting beam and a lower guide rail mounted securely onto the lower mounting beam. The horizontal movement system also includes a frame having an extended arm extending from its operational top frontal face, and a horizontal guidance unit mounting the frame on the upper and lower guide rails. The horizontal guidance unit comprises a plurality of vertically mounted load wheels that roll on the upper guide rail and a plurality of horizontally mounted guide wheels that roll on the lower guide rail.A prime mover positioned at the operational lower end of the frame is functionally coupled to a linear actuator for moving the frame horizontally.

[0018] A vertical movement system is mounted on the horizontal movement system, and an indexing movement system is coupled to the vertical movement system. A fork movement system is operatively connected to the indexing movement system, and a push-pull movement system is integrated with the fork movement system.

[0019] The vertical movement system includes an L-frame having a vertical section and a horizontal section, mounted internally to the vertical section of the frame. The L-frame includes a plurality of vertical guidance systems mounted on the L-frame’ s vertical section, with guide rollers rolling on guide rails on the internal vertical surfaces of the frame. A prime mover mounted at the rear top of the frame drives a shaft through a drive assembly, which may use one of a belt, chain, rope, or gear system. A counter load is positioned on both sides of the L-frame, wherein the counter load is configured to move along the outer vertical surfaces, and is coupled to the L-frame through a flexible element and a pulley system.

[0020] The indexing movement system includes a support plate, and a cabin holder. The support plate can be positioned on the operational top of the horizontal section of the L- frame. The cabin holder can be rotationally mounted at the lower end of the support plate through a slewing bearing. A prime mover mounted on top of the support plate drives the cabin holder rotationally through a gear and pinion arrangement.

[0021] The fork movement system includes a cabin configured to accommodate one or more cassettes during interchange. A prime mover is mounted sidewards to the cabin holder and engages a rack on the cabin to achieve linear motion.

[0022] The push-pull movement system includes a base plate within the cabin, wherein the based plate supports a cassette during interchange. The base plate has guide rails to enable inward and outward sliding of the cassette. A prime mover and control unit mounted on the base plate can slide linearly, and the control unit includes a servo motor coupled to a key for unlocking the cassette from a storage chamber or vehicle dock.

[0023] The system further includes a plurality of sensors for locating and aligning the cabin with a storage chamber in an interchange system or a vehicle dock. These sensors may include proximity sensors, cameras, motion sensors, or light sensors.

[0024] Embodiments herein disclose a method for automated cassette handling in a charging and interchange station, wherein the method comprises horizontally moving a framealong the upper and lower guide rails using the horizontal movement system, vertically moving the L-frame along the frame using the vertical movement system, rotationally indexing a cabin holder using the indexing movement system, linearly displacing a cabin within the cabin holder using the fork movement system, and extracting or inserting a cassette using the push-pull movement system.

[0025] Horizontally moving the frame involves activating the prime mover coupled to a linear actuator to displace the frame along the guide rails. Vertically moving the L-frame involves activating the prime mover to drive a drive assembly, translating rotational motion into linear movement of the L-frame while counterbalancing with the counter load. Rotationally indexing the cabin holder involves activating the prime mover to rotate the cabin holder via the gear and pinion arrangement.

[0026] Linearly displacing the cabin involves activating the prime mover to engage a rack and pinion to move the cabin. Extracting or inserting the cassette includes activating the prime mover to engage a rack and pinion attachment, moving the control unit linearly on the base plate, unlocking the cassette from the storage chamber or dock using the key, and pushing or pulling the cassette onto or off the base plate. Finally, the method includes locating and aligning the cabin with a storage chamber or vehicle dock using the sensors.BRIEF DESCRIPTION OF FIGURES

[0027] Embodiments herein are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the following illustrative drawings. Embodiments herein are illustrated by way of examples in the accompanying drawings, in which:

[0028] FIG. 1 illustrates an isometric view of an automated cassette handling system, according to embodiments as disclosed herein;

[0029] FIG. 2 illustrates a front view of an automated cassette handling system, according to embodiments as disclosed herein;

[0030] FIG. 3 illustrates a side view of an automated cassette handling system, according to embodiments as disclosed herein; and

[0031] FIG. 4 illustrates atop view of an automated cassette handling system, according to embodiments as disclosed herein.DETAILED DESCRIPTION

[0032] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as not to unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

[0033] For the purposes of interpreting this specification, the definitions (as defined herein) will apply, and whenever appropriate, the terms used in the singular will also include the plural and vice versa. It is to be understood that the terminology used herein is for the purposes of describing particular embodiments only and is not intended to be limiting. The terms “comprising”, “having” and “including” are to be construed as open-ended terms unless otherwise noted.

[0034] The words / phrases "exemplary", “example”, “illustration”, “in an instance”, “and the like”, “and so on”, “etc.”, “etcetera”, “e.g.,”, “i.e.,” are merely used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein using the words / phrases "exemplary", “example”, “illustration”, “in an instance”, “and the like”, “and so on”, “etc.”, “etcetera”, “e.g.,”, “i.e.,” is not necessarily to be construed as preferred or advantageous over other embodiments.

[0035] Embodiments herein may be described and illustrated in terms of blocks which carry out a described function or functions. These blocks, which may be referred to herein as managers, units, modules, hardware components or the like, are physically implemented by analogue and / or digital circuits such as logic gates, integrated circuits, microprocessors, microcontrollers, memory circuits, passive electronic components, active electronic components, optical components, hardwired circuits and the like, and may optionally be driven by a firmware. The circuits may, for example, be embodied in one or more semiconductor chips, or on substrate supports such as printed circuit boards and the like. The circuits constituting a block may be implemented by dedicated hardware, or by a processor (e.g., one or more programmed microprocessors and associated circuitry), or by a combination of dedicated hardware to perform some functions of the block and a processor to perform otherfunctions of the block. Each block of the embodiments may be physically separated into two or more interacting and discrete blocks without departing from the scope of the disclosure. Likewise, the blocks of the embodiments may be physically combined into more complex blocks without departing from the scope of the disclosure.

[0036] It should be noted that elements in the drawings are illustrated for the purposes of this description and ease of understanding and may not have necessarily been drawn to scale. For example, the flowcharts / sequence diagrams illustrate the method in terms of the steps required for understanding aspects of the embodiments as disclosed herein. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the present embodiments so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Furthermore, in terms of the system, one or more components / modules which comprise the system may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the present embodiments so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

[0037] The accompanying drawings are used to help easily understand various technical features and it should be understood that the embodiments presented herein are not limited by the accompanying drawings. As such, the present disclosure should be construed to extend to any modifications, equivalents, and substitutes in addition to those which are particularly set out in the accompanying drawings and the corresponding description. Usage of words such as first, second, third etc., to describe components / elements / steps is for the purposes of this description and should not be construed as sequential ordering / placement / occurrence unless specified otherwise.

[0038] The embodiments herein achieve a fully automated cassette handling system within a charging and interchange station. Referring now to the drawings, and more particularly to FIGS. 1 through 4, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.

[0039] The following terms and corresponding reference numerals have been referred to herein:- Automated Cassette handling System - Cassette - Horizontal Movement System - Upper Mounting Beam - Lower Mounting Beam - Upper Guide Rail - Lower Guide Rail - Horizontal Guidance Unit - Frame - Extended Arm - First Prime Mover - Linear Actuator - Vertical Movement System - Second Prime Mover - Drive Assembly - Counter Load - Load Guide rails - L-Frame - Vertical Section - Horizontal Section - Vertical Guidance Unit - Indexing Movement system - Third Prime Mover - Gear and Pinion - Support Plate - Cabin Holder424 - Cabin500 - Fork Movement system502 - Fourth Prime Mover504 - First Rack and Pinion600 - Push-Pull Movement system602 - Fourth Prime Mover604 - Control Box606 - Base Plate614 - Second Rack and pinion618 - Key

[0040] As referred to herein, the cassette 110 can be an electro-mechanical device comprising at least one electrical energy storage device, an ICU (Interface Control Unit), a TIU (Telematic Interface Unit), a BCU (Body Control Unit) and a plurality of sensors interconnected to behave as a unitary system.

[0041] FIGs. 1-4 disclose an automated cassette handling system 100. The system is provided with a horizontal movement system 200, a vertical movement system 300, an indexing movement system 400, a fork movement system 500, and a push-pull movement system 600. In an embodiment herein, the system 100 is further provided with a cassette locating system (not shown) such as sensors configured to locate a cassette 110, that is ready for interchange within the charging and interchange station or a dock in the vehicle. Example cassette locating systems include, but are not limited to, sensor-based systems (such as proximity, infrared, ultrasonic, or magnetic sensors), vision-based systems (such as cameras with image recognition), identification-based systems (such as Radio-Frequency Identification (RFID) or barcodes), mechanical position detectors (such as limit switches), and hybrid combinations thereof. These systems may be configured to detect, verify, and communicate the presence, position, and alignment of a cassette relative to a designated docking or compartment location within the station.

[0042] Further in an embodiment herein, the system 100 may also include a cassette orientation and interchange alignment system (not shown) configured to align the cassette handling system with the cassette ready for interchange. These systems work in conjunction tofacilitate the automated handling and interchange of cassettes 110 containing electrical energy storage devices.

[0043] The horizontal movement system 200 forms the base structure of the automated cassette handling system 100. The horizontal movement system 200 includes an upper mounting beam 202 and a lower mounting beam 204. The upper mounting beam 202 and the lower mounting beam 204 are firmly affixed to the floor of the charging and interchange station or on the ground. The mounting beams 202, 204 serve as support structures for the entire cassette handling system 100.

[0044] An upper guide rail 206 is mounted securely onto the upper mounting beam 202. A lower guide rail 208 is mounted securely onto the lower mounting beam 204. The guide rails 206, 208 are substantially rectangular in shape and facilitate the movement of a frame 218 along their length. The frame 218 is mounted on the upper guide rail 206 and the lower guide rail 208 using a horizontal guidance unit 212. In an embodiment herein, the horizontal guidance unit 212 may be equipped with a plurality of vertically mounted load wheels and a plurality of horizontally mounted guide wheels that are configured to roll on the upper guide rail 206 and lower guide rails 208, respectively. This configuration allows for smooth and precise horizontal movement of the frame 218 along the length of the guide rails. An extended arm 219 protrudes from the operational top frontal face of the frame 218, providing additional support and functionality to the system. In alternative embodiments, the frame 218 may be constructed from materials (such as, but not limited to, steel, aluminium, composite materials, and so on), depending on the specific requirements of strength and weight.

[0045] A first prime mover 220 is positioned at the operational lower end of the frame 218. The first prime mover 220 is functionally coupled to a linear actuator 222. The first prime mover 220 is configured for horizontally displacing the frame 218 along the length of the upper and lower mounting beams 202, 204, thereby facilitating efficient movement and positioning of the system 200. The prime mover 120 powers the linear actuator 122, which drives the system along the guide rails, facilitating efficient positioning and handling of cassettes. In additional embodiments, the first prime mover 220 may be one of an electric motor, hydraulic actuator, and a pneumatic system.

[0046] The vertical movement system 300 is integrated within the frame 218 and is responsible for the vertical displacement of the cassette handling components. The vertical movement system 300 includes an L-Frame 320. The L-Frame 320 comprises a vertical section322, and a horizontal section 324. The L-Frame 320 is mounted internal to the vertical section of the frame 218, wherein the L-Frame 320 is designed to move vertically along the length of the frame 218. This vertical movement can be facilitated by a plurality of vertical guidance systems 328 mounted on the vertical section 322 of the L-Frame 320. In an embodiment herein, the vertical guidance system 328 is provided with a plurality of guide rollers configured to roll on a plurality of guide rails (not shown) provided on either of the internal vertical surfaces of the frame 118. In an embodiment herein, the guidance systems can be, but not limited to, linear bearings, roller systems, and so on, and can be used to optimize the vertical movement.

[0047] The extended arms 219 provided on the frame 218 are configured to support the L-Frame 320. A vertical section 322 is mounted internally to the vertical section of the frame 218. The vertical movement system 300 is powered by a second prime mover 302, which is mounted on the rear top of the frame 218. The second prime mover 302 is coupled to a drive shaft through a drive assembly (not visible in FIG. 3), which translates the rotational motion into linear vertical movement of the L-Frame.

[0048] In an embodiment herein, the drive assembly 304 may be provided with a drive shaft (not shown) on the operational top of the frame 218 and supported by a plurality of bearings (not shown). The drive shaft is configured to provide vertical movement to the L- Frame 320 through a drive train. In an embodiment herein, the drive assembly 304 can be one of belt drive, chain drive, rope drive, combination of gear systems, and so on. In an embodiment herein, the prime mover 308 can be coupled to the drive shaft directly using a gear arrangement.

[0049] A counter load 312 is positioned on both sides of the frame 218. The counter load 312 is designed to move along the outer vertical surface of the frame 118 preferably on a plurality of load guide rails 314, wherein the counter load 312 can provide counterbalancing during vertical movement of the vertical movement system. The counter load 312 can help in maintaining balance and stability during operations, reducing the power requirements for vertical movement. In an embodiment herein, the counter load 312 is coupled to the rear end and the front end of the vertical section of the L-Frame 320 through a flexible element through a pulley system. In an embodiment herein, the flexible element 314 can be one of a chain, a belt, a rope, and so on.

[0050] When the second prime mover 302 is activated, the drive assembly 304 translates the rotational motion of the drive assembly 304 into the linear motion of the L-Frame320 through a drive train. Consequently, the L-Frame 320 moves vertically along the frame 118.

[0051] The operational top of the horizontal section 324 of the L-frame 320 is provided with a support plate 412. The support plate 412 houses the indexing movement system 400. A cabin holder 422 is rotationally mounted on the lower end of the support plate 412 through a slewing bearing. This arrangement allows for rotational movement of the cabin holder 422, which can be used for the indexing function of the system. The cabin holder 422 is designed to carry at least one cabin 424, which accommodates the cassette 110 during the interchange process.

[0052] The indexing movement system includes a third prime mover 402, wherein the third prime mover 402 can be mounted on top of the support plate 412. The third prime mover 402 can be configured to provide rotational movement to the cabin holder 422. In an embodiment herein, the third prime mover 402 is functionally coupled to the cabin holder 422 through a gear and pinion arrangement 404. In an embodiment herein, the gear and pinion arrangement 404 is mounted onto the support plate 412 and coupled to the cabin holder 422 through a flange arrangement. This rotational capability allows the system to orient the cabin 424 as needed for efficient cassette handling. Alternative embodiments may employ different drive mechanisms (such as, but not limited to, belt drives, direct drive systems, and so on) for the indexing movement.

[0053] The cabin holder 422 is configured to support at least one cabin 424. The cabin 424 is configured to accommodate one or more cassettes during the interchange of cassettes. The cabin 424 may be customized in various embodiments to accommodate different sizes and types of cassettes.

[0054] During indexing movement, the third prime mover 402 is powered on. The third prime mover 402 provides rotational movement to the gear and pinion arrangement 404. The gear and pinion arrangement 404 rotates the cabin holder 422, which houses the cabin 424.

[0055] In an embodiment herein, the gear and pinion arrangement 404 can be replaced with a different drivetrain (such as, but not limited to, a bet drive, rope, and pulley arrangement a chain and sprocket mechanism, and so on).

[0056] The fork movement system 500 is integrated within the cabin holder 422, wherein the fork movement system 500 can be responsible for the linear displacement of the cabin 424 within the cabin holder 422. The fork movement system 500 allows for precisepositioning of the cabin 424, which is essential for the smooth transfer of cassettes 110. The cabin holder 422 features a bent section designed to mimic a channel on both side edges. The bent configuration acts as a path for a plurality of guide rollers and load rollers coupled to the top of the cabin 424. The cabin 424 is further configured to accommodate the cassette 110 during the interchange of cassettes.

[0057] The fork movement system 500 is further provided with a fourth prime mover 502, wherein the fourth prime mover 502 can be mounted sidewards to the cabin holder 422. The cabin 424 is provided with a rack and pinion arrangement 504. The pinon can be mounted on the fourth prime mover 502 and configured to engage the rack, which can be functionally connected to the cabin 424. On the fourth prime mover 502 being activated, the pinion meshing with the rack of the rack and pinion 504 arrangement transforms the rotational motion into the linear movement of the cabin 424. The cabin 424 is supported by the guide rollers and load rollers (not shown) within the cabin holder 422, which enables the cabin 424 to move linearly. Alternative designs may incorporate different linear actuation mechanisms (such as, but not limited to, ball screw driver, rack and pinion systems, and so on) for enhanced precision or speed.

[0058] The push-pull movement system 600 is accommodated within the cabin 424. The push-pull movement system 600 includes a base plate 606 configured to support the cassette 110 during the interchange process. The base plate 606 is provided with a plurality of guide rails configured to support inward and outward sliding of the cassette 110 within the cabin 424. This system enables the precise extraction and insertion of cassettes from and into storage chambers or vehicle docks.

[0059] The system 600 further comprises a fourth prime mover 602, and a control unit 604 coupled with each other. The control unit 604 is configured to slide linearly on the base plate 606, while being supported by a plurality of linear guides mounted underneath. The base plate 606 is being mounted with a second rack and pinion 614 attachment. The fourth prime mover 602 is provided with the pinion, wherein the pinion mesh with the rack mounted on the base plate 606. These components work together to facilitate the insertion and extraction of cassettes from the cabin 424. Alternative embodiments may employ different linear drive systems such as belt drives or linear motors for this push-pull movement.

[0060] The control unit 604 is further provided with a servo motor coupled to a key 618. The key 618 is configured to unlock the cassette 110 from a storage chamber in anelectrical energy storage device interchange system or a dock on the vehicle, key 618 ensures secure locking and unlocking of the cassette during the interchange process. In additional embodiments, the key mechanism may be replaced with electronic or magnetic locking systems for enhanced security and speed.

[0061] The fourth prime mover 602 is activated, on the cassette being extracted from the interchange system or from the dock of a vehicle. The fourth prime mover 602 engages the second rack and pinion 614 to provide a liner movement to the control unit 604 which is mounted to the fourth prime mover 602. The control unit 604 engages the cassette and operates the key 618 to unlock the cassette 110 from the dock / storage chamber. The key 618 engages the cassette 110 to lock the cassette 110 to the control unit 604. The fourth prime mover 602 now engages the pinion 616 in a reverse rotational direction, and the control unit 604 moves in reverse, thereby pulling the cassette 110 onto the base plate 606. A plurality of guide wheels and load wheels (which are provided on the cassette) engage the cassette guide rails, and slide over the cassette guide rails. Once the cassette is extracted from the dock / compartment, the cassette handling system deposits the cassette within the dock of the vehicle or a dock of the interchange system.

[0062] To ensure accurate positioning and alignment, the system 100 is equipped with a plurality of sensors. These may include proximity sensors, cameras, motion sensors, or light sensors, which work in tandem to locate and align the cabin 424 with the dock in the electrical energy storage device interchange system or a dock on the vehicle.

[0063] The automated cassette handling system 100 is functionally coupled to the charging and interchange station. The charging and interchange station includes a central control system (not shown) that operates the automated cassette handling system 100 based on one or more received input(s). In an embodiment herein, the automated cassette handling system 100 may be provided with its own independent control system (not shown) configured to operate the automated cassette handling system 100.

[0064] The embodiments disclosed herein can be implemented through at least one software program running on at least one hardware device and performing network management functions to control the network elements. The elements include blocks which can be at least one of a hardware device or a combination of hardware devices and software modules.

[0065] In operation, the automated cassette handling system 100 works in a coordinated manner to locate, align, and transfer cassettes 110. The horizontal movement system 200 positions the frame 218 at the appropriate location along the charging and interchange station. The vertical movement system 300 then adjusts the height of the L-Frame 320 to align with the target cassette or storage location. The indexing movement system 400 rotates the cabin holder 422 to the correct orientation, while the fork movement system 500 extends or retracts the cabin 424 as needed. Finally, the push-pull movement system 600 engages with the cassette 110, either extracting it from its current location or inserting it into a new one.

[0066] This automated cassette handling system 100 represents a significant advancement in the field of cassette management, offering increased efficiency and reliability in the charging and interchange process. The system's modular design allows for potential upgrades or modifications to individual components, enhancing its adaptability to various operational environments and requirements.

[0067] The embodiments disclosed herein describe a fully automated cassette handling system within a charging and interchange station. Therefore, it is understood that the scope of the protection is extended to such a program and in addition to a computer readable means having a message therein, such computer readable storage means contain program code means for implementation of one or more steps of the method, when the program runs on a server or mobile device or any suitable programmable device. The method is implemented in at least one embodiment through or together with a software program written in e.g., Very high-speed integrated circuit Hardware Description Language (VHDL) another programming language, or implemented by one or more VHDL or several software modules being executed on at least one hardware device. The hardware device can be any kind of portable device that can be programmed. The device may also include means which could be e.g., hardware means e.g., an ASIC, or a combination of hardware and software means, e.g. an ASIC and an FPGA, or at least one microprocessor and at least one memory with software modules located therein. The method embodiments described herein could be implemented partly in hardware and partly in software. Alternatively, the invention may be implemented on different hardware devices, e.g., using a plurality of CPUs.

[0068] The embodiments described herein have several technical advantages including, but not limited to, the realization of an automated cassette handling system,- that enables fully automated handling of cassettes without requiring manual intervention;- that significantly reduces the time required for interchange operations, thereby minimizing vehicle downtime;- that ensures safe and precise alignment of the cassette with the vehicle or station, reducing the risk of operational errors;- that improves operator safety by eliminating direct contact with heavy and high-energy components;- that enhances the reliability and consistency of the interchange process even under variable environmental and operational conditions;- that allows scalability to handle higher volumes of vehicles efficiently as demand increases;- that provides adaptability to accommodate a range of storage device sizes, weights, and configurations used in different vehicles;- that minimizes wear and tear on the storage devices, vehicles, and infrastructure by ensuring controlled and accurate handling;- that reduces dependency on skilled labour, thereby lowering operational costs and simplifying station management;- that facilitates seamless integration into existing charging and interchange infrastructure without extensive modifications; and- that improves monitoring and control of the interchange process through sensor-assisted feedback and automation.

[0069] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and / or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments and examples, those skilled in the art will recognize that the embodiments and examples disclosed herein can be practiced with modification within the scope of the embodiments as described herein.

Claims

STATEMENT OF CLAIMSWe claim:

1. An automated cassette handling system comprising: a horizontal movement system (200) having an upper mounting beam (202) and a lower mounting beam (204) firmly affixed to one of a charging and interchange station, and a ground; a vertical movement system (300) mounted on the horizontal movement system (200); an indexing movement system (400) coupled to the vertical movement system (300); a fork movement system (500) operatively connected to the indexing movement system (400); and a push-pull movement system (600) integrated with the fork movement system (500).

2. The automated cassette handling system as claimed in claim 1, wherein the horizontal movement system (200) includes an upper guide rail (206) mounted securely onto the upper mounting beam (202) and a lower guide rail (208) mounted securely onto the lower mounting beam (204).

3. The automated cassette handling system as claimed in claim 2, wherein the horizontal movement system (200) includes a frame (218) having an extended arm (219) extending from an operational top frontal face of the frame (218), a horizontal guidance unit (212) mounting the frame (218) on the upper guide rail (206) and the lower guide rail (208), and a first prime mover (220) positioned at an operational lower end of the frame (218) and a linear actuator (222) functionally coupled to the first prime mover (220), wherein the horizontal guidance unit (212) includes a plurality of vertically mounted load wheels configured to roll on the upper guide rail (206) and a plurality of horizontally mounted guide wheels configured to roll on the lower guide rail (208).

4. The automated cassette handling system as claimed in claim 1, wherein the vertical movement system (300) includes an L-Frame (320) having a vertical section (322) and a horizontal section (324), wherein the L-Frame (320) is mounted internally to a vertical section of the frame (218).

5. The automated cassette handling system as claimed in claim 4, wherein the vertical movement system (300) includes a plurality of vertical guidance systems (328) mounted on the vertical section (322) of the L-Frame (320), wherein each vertical guidance system (328) includes a plurality of guide rollers configured to roll on a guide rail provided on either of internal vertical surfaces of the frame (218).

6. The automated cassette handling system as claimed in claim 4, wherein the vertical movement system (300) further includes: a second prime mover (302) mounted on a rear top of the frame (218); a drive shaft (306) coupled to the second prime mover (302); and a drive assembly (304) connecting the second prime mover (302) to the drive shaft (306, wherein the drive assembly (304) is one of a belt drive, a chain drive, a rope drive, and a combination of gear systems.

7. The automated cassette handling system as claimed in claim 6, wherein the vertical movement system (300) further includes a counter load (312) positioned on both sides of the frame (218), wherein the counter load (312) is coupled to a rear end and a front end of the vertical section of the L-Frame (320) through a flexible element and a pulley system, and is configured to move along an outer vertical surface of the frame (218).

8. The automated cassette handling system as claimed in claim 1, wherein the indexing movement system (400) includes a support plate (412) provided on an operational top of the horizontal section (324) of the L-frame (320), wherein the indexing movement system (400) includes a cabin holder (422) rotationally mounted on a lower end of the support plate (412) through a slewing bearing, and a third prime mover (402) mounted on top of the support plate (412), wherein the third prime mover (402) is configured to provide rotational movement to the cabin holder (422).

9. The automated cassette handling system as claimed in claim 8, wherein the indexing movement system (400) includes a gear and pinion arrangement (404) functionally coupling the third prime mover (402) to the cabin holder (422).

10. The automated cassette handling system as claimed in claim 1, wherein the fork movement system (500) includes a cabin (424), and a fourth prime mover (502), wherein the cabin (424) is configured to accommodate one or more cassettes andincludes a rack configured to engage a pinion on the fourth prime mover (502), and the fourth prime mover (502) is mounted sidewards to the cabin holder (422).

11. The automated cassette handling system as claimed in claim 1, wherein the push-pull movement system (600) includes a base plate (606) provided within the cabin (424), a fourth prime mover (602), and a control unit (604) coupled to the fourth prime mover (602) and configured to slide linearly on the base plate (606), wherein the base plate (606) includes a plurality of guide rails configured to support inward and outward sliding of the cassette (110) within the cabin (424), and is configured to support a cassette (110) during an interchange process.

12. The automated cassette handling system as claimed in claim 11, wherein the control unit (604) includes a servo motor coupled to a key (618), wherein the key (618) is configured to unlock the cassette (110) from a dock in an electrical energy storage device interchange system or a dock on a vehicle.

13. The automated cassette handling system as claimed in claim 1, wherein the system includes a plurality of sensors for locating and aligning the cabin (424) with a storage chamber in an electrical energy storage device interchange system or a dock on a vehicle, wherein the sensors can be at least one of proximity sensors, cameras, motion sensors, and light sensors.

14. A method for automated cassette handling in a charging and interchange station, the method comprising: horizontally moving a frame (218) along an upper guide rail (206) and a lower guide rail (208) using a horizontal movement system (200); vertically moving an L-Frame (320) along the frame (218) using a vertical movement system (300); rotationally indexing a cabin holder (422) using an indexing movement system (400); linearly displacing a cabin (424) within the cabin holder (422) using a fork movement system (500); and extracting or inserting a cassette (110) using a push-pull movement system(600).

15. The method as claimed in claim 14, wherein horizontally moving the frame (218) includes activating a first prime mover (220) coupled to a linear actuator (222) to displace the frame (218) along the upper guide rail (206) and the lower guide rail (208).

16. The method as claimed in claim 14, wherein vertically moving the L-Frame (320) includes: activating a second prime mover (302) to drive a drive assembly (304); translating rotational motion of the drive assembly (304) into linear motion of the L-Frame (320); and counterbalancing the vertical movement using a counter load (312).

17. The method as claimed in claim 14, wherein rotationally indexing the cabin holder (422) includes activating a third prime mover (402) to rotate the cabin holder (422) through a gear and pinion arrangement (404).

18. The method as claimed in claim 14, wherein linearly displacing the cabin (424) includes activating a fourth prime mover (502) to engage a rack on the cabin (424) with a pinion, transforming rotational motion into linear movement of the cabin (424).

19. The method as claimed in claim 14, wherein extracting or inserting the cassette (110) includes: activating a fourth prime mover (602) to engage a second rack and pinion (614) attachment; moving a control unit (604) linearly on a base plate (606); operating a key (618) to unlock the cassette (110) from a dock; and pulling or pushing the cassette (110) onto or off the base plate (606).

20. The method as claimed in claim 14, wherein the method includes locating and aligning the cabin (424) with a dock in an electrical energy storage device interchange system or a dock on a vehicle using a plurality of sensors.

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