Modular fixture alignment unit for simulating electrical energy storage device interchange in vehicles

Abstract

Disclosed herein is a modular fixture alignment unit including a dock fixture configured to accommodate a plurality of electrical energy storage devices, and an aligner assembly designed to align the dock fixture within the reach of a battery handling system of a charging and interchange station. The dock fixture comprises a central platform supported by multiple mounting columns that are mounted on the aligner assembly. An upper platform is mounted on the central platform and supported by several support columns. A lower platform is located beneath the central platform, supported by support columns. Berths are formed above each of the platforms for accommodating energy storage devices. Also disclosed is an aligner assembly comprising a X-platform and a Y-platform, each of which are linearly displaced by respective rack-and-pinion units driven by a prime mover, and a Z-platform with a lift.

Description

Modular fixture alignment unit for simulating electrical energy storage device interchange in vehiclesCROSS REFERENCE TO RELATED APPLICATIONThis application is based on and derives the benefit of Indian Provisional Application IN202441065064, the contents of which are incorporated herein by reference.TECHNICAL FIELD

[0001] Embodiments disclosed herein relate to interchanging electrical energy storage devices in a vehicle, and more particularly to a modular fixture alignment unit for simulating electrical energy storage device interchange in a vehicle.BACKGROUND

[0002] Environmental concerns, such as reducing greenhouse gas emissions and mitigating air pollution, are compelling drivers for transitioning from internal combustion engine (ICE) vehicles to electric vehicles (EVs). Additionally, the increasing accessibility of renewable energy sources and advancements in battery technology have made EVs more practical and cost-effective alternatives. These factors, combined with governmental incentives and stricter regulations on emissions, are accelerating the adoption of EVs globally.

[0003] However, despite the numerous advantages of EVs, certain challenges persist, hindering their widespread adoption. Among these challenges, range anxiety, and long charging times are significant deterrents for potential EV buyers. Traditional charging infrastructure is often insufficient to address these concerns, especially for heavy electric vehicles (HEVs) used in commercial applications. In response to these challenges, electrical energy storage device charging and interchange stations emerge as promising solutions that can significantly reduce charging times and alleviate range anxiety by quickly exchanging depleted batteries for fully charged ones.

[0004] Implementing battery swapping stations for HEVs presents challenges, particularly concerning the logistics of accommodating diverse battery placements across different vehicle models. Automatic battery handling systems (BHS) are essential components of electrical energy storage device charging and interchange stations, but their operational reach must align with the varying locations of electrical energy storage devices in different vehicles. Conducting comprehensive testing of BHS operational reach requires access tomultiple heavy vehicles with electrical energy storage devices mounted in various configurations an impractical undertaking at production sites.

[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 modular fixture alignment unit to simulate the interchange of electrical energy storage devices in vehicles, enabling efficient testing and optimization of electrical energy storage device interchange technologies for Heavy Electric Vehicles (HEVs).

[0007] Another object of embodiments herein is to disclose a modular fixture alignment unit for the simulation of electrical energy storage device interchange in a vehicle that accurately depicts the placement and specifications of electrical energy storage devices within each vehicle.

[0008] Yet, another object of embodiments herein is to disclose a modular fixture alignment unit for the simulation of electrical energy storage device interchange in a vehicle replicating the functionalities and limitations of real -world automatic battery handling systems.

[0009] Still, another object of embodiments herein is to disclose a modular fixture alignment unit for the simulation of electrical energy storage device interchange in a vehicle that would help optimize the design and performance of electrical energy storage device interchange stations.

[0010] Still, another object of embodiments herein is to disclose a modular fixture alignment unit for the simulation of electrical energy storage device interchange in a vehicle that is cost-effective, easy to handle, and requires minimal maintenance.

[0011] Still, another object of embodiments herein is to disclose a modular fixture alignment unit that supports controlled and repeatable testing of battery handling system reachability across multiple energy storage device layouts.

[0012] Still, another object of embodiments herein is to disclose a modular fixture alignment unit that enables early-stage design validation of electrical energy storage device interchange stations without the need for multiple vehicle prototypes.

[0013] Still, another object of embodiments herein is to disclose a modular fixture alignment unit that minimizes logistical challenges associated with real -vehicle-based testing of battery interchange systems.

[0014] Still, another object of embodiments herein is to disclose a modular fixture alignment unit that facilitates flexible configuration to accommodate diverse mounting orientations and placements of electrical energy storage devices in various vehicle models.

[0015] Still, another object of embodiments herein is to disclose a modular fixture alignment unit that contributes to reducing range anxiety by accelerating the deployment of efficient electrical energy storage device interchange infrastructure for electric vehicles.

[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 a modular fixture alignment unit, which includes a dock fixture configured to accommodate a plurality of electrical energy storage devices, and an aligner assembly designed to align the dock fixture within the reach of a battery handling system of a charging and interchange station. The dock fixture comprises a central platform supported by multiple mounting columns that are mounted on the aligner assembly. A central berth is defined above this central platform to house one or more storage devices. An upper platform is mounted on the central platform and supported by several support columns, forming an upper berth for accommodating one or more storage devices. Similarly, a lower platform is located beneath the central platform, supported by support columns, thereby forming a lower berth for accommodating one or more storage devices.

[0018] The central, upper, and lower platforms are configured to be mounted with multiple cabins that are designed to secure the storage devices. The aligner assembly comprises a Z-aligner for vertical alignment, a Y-aligner for depth-wise alignment, and an X-aligner for horizontal alignment. The Z-aligner includes Z-actuators on either side, which provide vertical movement to the dock fixture. These actuators are placed within bodies that also serve as load-bearing columns for the entire unit. The Y-aligner includes base plates mounted on the Z- actuators, guide rails provided on these plates, and height blocks that slide along the guide rails. A Y-actuator on the base plates allows movement of the dock fixture in the Y-direction. Similarly, the X-aligner includes base plates mounted on the height blocks, with guide rails and additional height blocks configured to slide on the guide rails, and an X-actuator that facilitates movement in the X-direction.

[0019] The dock fixture may also include one or more visual and proximity sensors to enable automatic alignment within the reach area of the battery handling system.

[0020] Additionally, the modular fixture alignment unit may have a base platform mounted on columns, with guide rails allowing linear displacement of an X-platform via a rack and pinion system driven by a prime mover. A Y-platform is mounted on top of the X-platform and is displaceable along guide rails in the Y-direction, wherein the Y-platform is driven by a rack and pinion mechanism. The vertical movement of the Y-platform is enabled by slider columns on the Y-platform, with a Z-platform mounted to slide along them. The Z-platform is vertically movable via a lift mechanism, which may be one of hydraulic, pneumatic, hydropneumatic, jack-based, scissor-type, and so on. The dock fixture is mounted on this Z-platform.BRIEF DESCRIPTION OF FIGURES

[0021] 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:

[0022] FIG. 1 illustrates an isometric view of a modular fixture alignment unit, according to embodiments as disclosed herein;

[0023] FIG. 2 illustrates a front view of a dock fixture of the modular fixture alignment unit, according to embodiments as disclosed herein;

[0024] FIG. 3 illustrates a front view of an aligner assembly of the modular fixture alignment unit, according to embodiments as disclosed herein;

[0025] FIG. 4 illustrates a top view of the modular fixture alignment unit, according to embodiments as disclosed herein;

[0026] FIG. 5 illustrates an isometric view of the dock fixture of the modular fixture alignment unit, according to embodiments as disclosed herein;

[0027] FIG. 6 illustrates a sectional front view of the dock fixture of the modular fixture alignment unit, according to embodiments as disclosed herein;

[0028] FIG. 7A illustrates a sectional front view of the dock fixture of the modular fixture alignment unit depicting alignment in the Z direction, according to embodiments as disclosed herein;

[0029] FIG. 7B illustrates a sectional side view of the dock fixture of the modular fixture alignment unit depicting alignment in the Z direction, according to embodiments as disclosed herein;

[0030] FIG. 8 A illustrates a sectional top view of the dock fixture of the modular fixture alignment unit depicting alignment in the Y direction, according to embodiments as disclosed herein;

[0031] FIG. 8B illustrates a sectional side view of the dock fixture of the modular fixture alignment unit depicting alignment in the Y direction, according to embodiments as disclosed herein;

[0032] FIG. 9A illustrates a sectional top view of the dock fixture of the modular fixture alignment unit depicting alignment in the X, according to embodiments as disclosed herein;

[0033] FIG. 9B illustrates a sectional front view of the dock fixture of the modular fixture alignment unit depicting alignment in the X direction, according to embodiments as disclosed herein;

[0034] FIG. 10 illustrates an isometric view of an aligner assembly of the modular fixture alignment unit, according to embodiments as disclosed herein;

[0035] FIG. 11 illustrates an isometric view of an aligner assembly of the modular fixture alignment unit, according to embodiments as disclosed herein;

[0036] FIG. 12 illustrates a front view of an aligner assembly of the modular fixture alignment unit, according to embodiments as disclosed herein; and

[0037] FIG. 13 illustrates a sectional front view of an aligner assembly of the modular fixture alignment unit, according to embodiments as disclosed herein.DETAILED DESCRIPTION

[0038] 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.

[0039] 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.

[0040] 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.

[0041] 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.

[0042] 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.

[0043] 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.

[0044] The embodiments herein achieve a modular fixture alignment unit that is cost- effective and practical solution for simulating the interchange of electrical energy storage devices in vehicles. The modular fixture alignment unit enables accurate testing of battery handling systems, supports diverse device placements, and facilitates faster development and optimization of interchange infrastructure. Referring now to the drawings, and more particularly to FIGS. 1 through 13, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.

[0045] The following terms / components / systems and corresponding reference numerals have been referred to herein:100 - Modular Fixture Alignment Unit110 - Dock Fixture112 - Mounting Columns114 - Central Platform116 - Central Berth118 - Cabin120 - Support Column122 - Upper Platform124 - Upper Berth126 - Lower Platform128 - Lower Berth140 - Electrical energy storage device150 - Aligner Assembly155 - Height Block160 - Z- Aligner162 - Z-actuator164 - Body170 - Y- Aligner172 - First Base Plate174 - First Rail Guides176 - Y-actuator180 - X- Aligner182 - Second Base Plate184 - Second Rail Guides186 - X-actuator200 - BHS Reach Area212 - Support Column250 - Aligner Assembly255 - Base Platform260 - Z-Platform262 - Lift264 - Slider Column270 - Y-Platform272 - Second Prime Mover274 - Second Rack And Pinion Unit276 - Second plurality of Guide Rails280 - X-Platform282 - First Prime Mover284 - First Rack And Pinion Unit286 - First plurality of Guide Rails290 - Prime Mover

[0046] FIGs. 1 - 9B discloses a modular fixture alignment unit 100. The modular fixture is provided with a dock fixture 110 mounted on an aligner assembly 150. The dock fixture 110 can accommodate a multiple energy storage devices 200 based on the position of the electrical energy storage device provided on a commercial vehicle (for example, a heavy electric vehicle (HEV)). The aligner assembly 150 is configured to align an electrical energy storage device cabin 118 within the area of reach of a battery handling system (BHS) of a charging and interchange station.

[0047] The dock fixture 110 features a central platform 114 supported by multiple mounting columns 112 mounted on the aligner assembly 150. The space above the central platform 114 defines a central berth 116 designed to house multiple electrical energy storage devices 140. An upper platform 122 is mounted on the central platform 114, wherein the upperplatform 122 is supported by a plurality of support columns 120. The area above the upper platform 122 creates an upper berth 124 designed to accommodate a plurality of electrical energy storage devices 140. A lower platform 126 is situated beneath the central platform 114, also supported by a plurality of support columns 120. The region above the lower platform 126 constitutes a lower berth 128 configured to accommodate a plurality of electrical energy storage devices 140.

[0048] In an embodiment herein, the central platform 114, the upper platform 122, and the lower platform 126 are further configured to be equipped with a plurality of cabins 118. The plurality of cabins 118 are specialized compartments, wherein each of the plurality of cabins can securely accommodate at least one electrical energy storage device 140. The cabins 118 can be customized to fit various sizes and capacities of energy storage devices, ranging from 50kWh to 250kWh, allowing for versatile simulation of different vehicle configurations.

[0049] The upper berth 124, central berth 116, and lower berth 128 are designed to replicate the placement of electrical energy storage devices found in various HEVs. This configuration allows the dock fixtures to be aligned with the reach of the BHS 200, based on the location of the electrical energy storage device within the heavy electric vehicles. The dock fixtures facilitate the calibration of the heavy electric vehicles' resting positions during the interchange of electrical energy storage devices 140 in the electrical energy storage device charging and interchange station.

[0050] The aligner assembly 150 comprises a Z-Aligner 160 configured to align the dock fixture 110 in a Z direction (i.e., a vertical direction), a Y-Aligner 170 configured to align the dock fixture 110 in a Y direction (i.e., a depth direction), and an X-Aligner 180 configured to align the dock fixture 110 in a X direction (i.e., a horizontal direction).

[0051] The Z-aligner 160 is equipped with a Z-actuator 162 configured to provide vertical movement along the Z direction (i.e., lift, or vertically) to the dock fixture 110. The Z- actuators 162 are housed within a body 164. The body 164 serves as a load-bearing column to the entire modular fixture alignment unit 100.

[0052] The Y-aligner 170 comprises a first base plate 172 mounted on one or more of the Z-actuators 162. The first base plate 172 is equipped with a first plurality of guide rails 174 that support and guide a plurality of height blocks 155. The height blocks 155 are configured to slide on the first plurality of guide rails 174. A Y-actuator 176 is installed on each of the base plates 172 providing movement to the dock fixtures in the Y direction (i.e., depth). In anembodiment herein, Y-actuators 176 are mounted on each of the first base plates 172, wherein the Y-actuators 176 can operate independently to align the dock fixture 110 at an angle to the charging and interchange station. This feature is particularly useful for correcting any misalignment of the vehicle with the front section of the charging and interchange station.

[0053] The X-aligner 180 features a second base plate 182 mounted on one or more of the height blocks 155. Similar to the Y-Aligner, the second base plate 182 is equipped with a second plurality of guide rails 184 that support and provide guidance to the plurality of height blocks 155. The height blocks 155 are configured to slide on the second plurality of guide rails 184. An X-actuator 186 is installed on each of the base plates 182 providing movement to the dock fixtures in the X-direction (i.e., horizontal).

[0054] The dock fixture 100 is mounted on the height block 155 of the X-aligner allowing it to be precisely positioned within the reach of the BHS 200 at the electrical energy storage device charging and interchange station.

[0055] The modular fixture alignment unit 100 simulates the different types of vehicles (such as, but not limited to, trucks, buses, and so on) with electrical energy storage devices mounted at various locations. By using the modular fixture alignment unit 100 to simulate the alignment, the proper position of the electric vehicle with respect to the BHS can be determined, enabling the BHS to easily interchange the depleted electrical energy storage devices in the vehicle for a charged electrical energy storage device without any hassle.

[0056] In an embodiment herein, the Z-actuators 162, the Y-actuators 176, and the X- actuators 186 can be implemented using different technologies. In an embodiment herein, the Z-actuators 162, the Y-actuators 176, and the X-actuators 186 may include pneumatically operated hydraulic actuators or rack and pinion gear actuators or screwjack actuators, or any other suitable actuators. The choice of actuator technology can be based on factors such as precision requirements, load capacity, and operational environment.

[0057] FIGs. 10-13 disclose an aligner assembly 250 of the modular fixture alignment unit 100. The aligner assembly comprises a base platform 255 mounted on a plurality of columns. The base platform 255 is provided with a first plurality of guide rails 286, wherein the first plurality of guide rails 286 are configured to provide linear movement to an X-platform 280.

[0058] The X-platform 280 is displaceably mounted on the base platform 255. The X- platform 280 is configured to be displaced linearly in the X-direction over the first plurality ofguide rails 286. A first prime mover 282 is rigidly mounted onto the X-platform 280. The first prime mover 282 is configured to provide displacement to the X-platform 280 along the guide rails 286 using a first rack and pinion unit 284. The pinion from the first rack and pinion unit 284 is mounted on the open end of the rotational shaft of the first prime mover 282. The rack from the first rack and pinion unit 284 is mounted on the base platform 255 such that the pinion is always in engagement with the rack of the first rack and pinion unit 284. As the first prime mover 282 is activated, the rotational movement of the prime mover shaft is converted to linear movement of the X-platform 280 via the first rack and pinion unit 284.

[0059] A Y-platform 270 is displaceable and mounted on the operational top of the X- platform 250. The Y-platform 270 is configured to be displaced in the Y-direction over a second plurality of guide rails 276. A second prime mover 272 is rigidly mounted onto the Y- platform 270. The second prime mover 272 is configured to provide displacement to the Y- platform 270 along the second plurality of guide rails 276 using a second rack and pinion unit 274. The pinion of the second rack and pinion unit 274 is mounted on the open end of the rotational shaft of the second prime mover 272. The rack of the second rack and pinion unit 274 is mounted on the X-platform 280 such that the pinion is always in engagement with the rack of the second rack and pinion unit 274. As the second prime mover 272 is activated, the rotational movement of the prime mover shaft is converted to linear movement of the Y- platform 270 via the second rack and pinion unit 274.

[0060] A plurality of slider columns 264 are vertically mounted on the Y-platform 270. A Z-platform 260 has a plurality of through holes complimentary to the slider columns 264, and the Z-platform 260 is displaceably mounted on the slider columns 264. The Z-platform 260 is configured to slide vertically on the slider columns 264. The Z-platform 260 is further mounted onto a lift 262. The lift 262 is configured to enable vertical movement of the Z- platform 260. The dock fixture 110 is configured to be mounted on the Z-platform 260.

[0061] In an embodiment herein, the lift 262 can be one of a hydraulic lift, a pneumatic lift, a hydro-pneumatic lift, a jack lift a scissor lift, and so on. In some embodiments, the first and second plurality of guide rails 276, 286 can be replaced with linear bearings or air bearings for smoother motion and reduced friction. The material of the platforms and support columns can be selected based on the required load-bearing capacity and environmental conditions, with options including, but not limited to, high-strength aluminium alloys, stainless steel, composite materials, and so on.

[0062] In an embodiment herein, the dock fixtures 110 are mounted on the aligner assembly 150 using one or more fasteners.

[0063] In an embodiment herein, the dock fixture 110 is provided with one or more visual sensors and proximity sensors (not shown) to enable auto-alignment within the BHS reach area 200 of the electrical energy storage device charging and interchange station. The one or more visual sensors and proximity sensors can provide real-time feedback on the position and orientation of the dock fixture, allowing for precise adjustments to ensure optimal alignment.

[0064] In an embodiment herein, the dock fixture 100 is configured to accommodate electrical energy storage devices of different sizes, shapes, and capacities (as required). Additionally, the materials used for the platforms and support structures can be varied to optimize weight, durability, and cost-effectiveness based on specific operational requirements.

[0065] In an embodiment herein, the cabin 118 is attached to the dock fixture using fasteners. A variety of cabin 118 for different capacity energy storages (such as, but not limited to, 250kWh, 200kWh, 150kWh, lOOkWh, and 50kWh) can be provided on the dock fixture.

[0066] The versatility of the modular fixture alignment unit 100 allows it to simulate different vehicle configurations. For instance, in truck simulations, the electrical energy storage devices can be placed in the central berth 116 or the lower berth 128. Under the dock fixture, while in buses, it can be in the central berth 116 (within the body), the upper berth 124 (over the roof), or the lower berth 128 (under the chassis). In an example herein, the dock fixture is designed to position 50kWh and lOOkWh energy storages under the frame, and 250kWh, 200kWh, 150kWh, 50kWh, and lOOkWh energy storages above the frame.

[0067] The modular nature of the dock fixture 110 allows for easy customization and upgrades. For instance, the cabins 118 can be designed with quick-release mechanisms for rapid reconfiguration of the berths to accommodate different energy storage device configurations. This modularity extends the utility of the dock fixture 110, making it adaptable to a wide range of current and future HEV designs.

[0068] The modular fixture alignment unit 100 provides a flexible and efficient solution for simulating various electric vehicle configurations and optimizing the alignment process for battery interchange operations. By accurately replicating the positions of electrical energy storage devices in different vehicle types, it enables the development and testing of efficientbattery handling systems, ultimately contributing to the advancement of electric vehicle technology and infrastructure.

[0069] The embodiments described herein have several technical advantages including, but not limited to, the realization of a modular fixture alignment unit,- that enables realistic simulation of electrical energy storage device interchange operations across various vehicle configurations;- that facilitates precise multi-directional alignment to replicate actual positioning conditions required during battery handling;- that allows repeatable testing of interchange processes to ensure system reliability and performance consistency;- that supports efficient validation of alignment strategies for diverse vehicle designs without using physical vehicles;- that minimizes operational errors in battery handling by accurately reproducing vehiclespecific energy storage layouts;- that accelerates the development and calibration of battery handling systems through controlled simulation environments;- that enables flexibility in testing a wide range of energy storage configurations commonly found in heavy electric vehicles;- that reduces dependency on live vehicle access during the testing and design phase of interchange infrastructure;- that improves safety during validation by enabling off-vehicle simulation of storage device interchange mechanisms; and that enhances overall efficiency of energy storage interchange systems through optimized alignment and handling validation.

[0070] 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 employedherein 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 practised with modification within the scope of the embodiments as described herein.

Claims

STATEMENT OF CLAIMSWe claim:

1. A modular fixture alignment unit (100) comprising: a dock fixture (110) configured to accommodate a plurality of electrical energy storage devices (140); an aligner assembly (150) configured to align the dock fixture (110) within reach of a battery handling system (200) of a charging and interchange station; a central platform (114) supported by a plurality of mounting columns (112) mounted on the aligner assembly (150); a central berth (116) defined above the central platform (114); an upper platform (122) mounted on the central platform (114) supported by a plurality of support columns (120); an upper berth (124) formed above the upper platform (122); a lower platform (126) situated beneath the central platform (114), supported by the plurality of support columns (120); and a lower berth (128) constituted above the lower platform (126).

2. The modular fixture alignment unit (100) as claimed in claim 1, wherein at least one of the central platform (114), the upper platform (122), and the lower platform (126) are configured to be mounted with at least one cabin (118) each, wherein each of the cabin (118) is configured to accommodate and secure at least one electrical energy storage device (140).

3. The modular fixture alignment unit (100) as claimed in claim 1, wherein the aligner assembly (150) comprises: a Z-Aligner (160) configured to align the dock fixture (110) in a Z direction; a Y-Aligner (170) configured to align the dock fixture (110) in a Y direction; and an X- Aligner (180) configured to align the dock fixture (110) in an X direction.

4. The modular fixture alignment unit (100) as claimed in claim 3, wherein the Z-aligner (160) has Z-actuators (162) on each of the Z-aligner (160), wherein the Z-actuators (162) areplaced within a body (164), and is configured to provide vertical movement along the Z direction to the dock fixture (110).

5. The modular fixture alignment unit (100) as claimed in claim 4, wherein the body (164) acts as a load-bearing column to the modular fixture alignment unit (100).

6. The modular fixture alignment unit (100) as claimed in claim 4, wherein the Y-aligner (170) comprises: a first base plate (172) mounted on each of the Z-actuators (162); a first plurality of guide rails (174) provided on the first base plate (172); a plurality of height blocks (155) configured to slide on the first plurality of guide rails (174); and a Y-actuator (176) provided on the first pair of base plates (172), wherein the Y-actuator (176) is configured to provide movement to the dock fixtures (110) in a Y direction.

7. The modular fixture alignment unit (100) as claimed in claim 4, wherein the X-aligner (180) comprises: a second base plate (182) mounted on each of the height blocks (155); a second plurality of guide rails (184) provided on the second base plate (182), wherein the plurality of height blocks (155) are configured to slide on the second plurality of guide rails (184); and an X-actuator (186) provided on the second pair of base plates (182), wherein the X- actuator (186) is configured to provide movement to the dock fixtures (110) in the X direction.

8. The modular fixture alignment unit (100) as claimed in claim 1, wherein the dock fixture (110) is provided with one or more visual sensors and proximity sensors to auto-align within the battery handling system reach area (200) of the electrical energy storage device charging and interchange station.

9. A modular fixture alignment unit (100) comprising: a base platform (255) mounted on a plurality of mounting columns; a first plurality of guide rails (286) provided on the base platform (255);an X-platform (280) displaceably mounted on the base platform (255) and configured to be displaced linearly in the X-direction over the first plurality of guide rails (286); a first prime mover (282) rigidly mounted onto the X-platform (280) and configured to provide displacement to the X-platform (280) along the first plurality of guide rails (286) using a first rack and pinion unit (284); a Y-platform (270) displaceably mounted on the operational top of the X-platform (280) and configured to be displaced in the Y-direction over a second plurality of guide rails (276); a second prime mover (272) rigidly mounted onto the Y-platform (270) and configured to provide displacement to the Y-platform (270) along the second plurality of guide rails (276) using a second rack and pinion unit (274); a plurality of slider columns (264) vertically mounted on the Y-platform (270); a Z-platform (260) having a plurality of through holes complimentary to the slider columns (264) displaceably mounted on the slider columns (264) and configured to slide vertically on the slider columns (264); a lift (262) configured to enable vertical movement of the Z-platform (260); and a dock fixture (110) configured to be mounted on the Z-platform (260).

10. The modular fixture alignment unit (100) as claimed in claim 9, wherein the lift (262) is one of a hydraulic lift, a pneumatic lift, a hydro-pneumatic lift, a jack lift, and a scissor lift.

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