A lock and unlock mechanism for an electrical energy storage device handling system

Abstract

Disclosed herein is an electrical energy storage device handling system comprising a loading platform configured to accommodate at least one cassette, and a control unit provided on the platform to push or pull the cassette(s) for interchange. A prime mover coupled to the control unit provides linear movement using a rack and pinion mechanism. The control unit is also equipped with a locking and unlocking mechanism, a key, and a switch arm that is configured to rotate. Additionally, the electrical energy storage device handling system includes a left side limit switch and a right side limit switch, both of which pause the system's operation when engaged by the switch arm.

Description

A lock and unlock mechanism for an electrical energy storage device handling systemCROSS REFERENCE TO RELATED APPLICATIONThis application is based on and derives the benefit of Indian Provisional Application IN202441065079, the contents of which are incorporated herein by reference.TECHNICAL FIELD

[0001] Embodiments disclosed herein relate to a lock and unlock mechanism for an electrical energy storage device handling system, and more particularly to a lock and unlock mechanism for an electrical energy storage device handling system, wherein the electrical energy storage device can be in one of an electrical energy storage device exchange station, or a vehicle.BACKGROUND

[0002] Electrical energy storage device interchange has emerged as a pivotal solution for heavy vehicles, addressing the challenge posed by the considerable weight of their electrical energy storage devices. In this interchange process, an Electrical energy storage device Handling System (BHS) assumes a critical role in ensuring seamless electrical energy storage device exchanges. The BHS disengages the electrical energy storage device from the vehicle or charging and interchange station, but also secures the electrical energy storage device in the vehicle or charging and interchange station itself. This is paramount due to the inherent risk of the electrical energy storage device becoming dislodged or damaged during the interchange procedure.

[0003] Given the substantial cost associated with each electrical energy storage device, even minor damage can prove financially burdensome. In cases of severe damage, the entire electrical energy storage device may necessitate replacement, resulting in significant expenditure. Consequently, there exists a pressing need for a locking and unlocking mechanism within the BHS that is both facile and efficient, safeguarding the integrity of the electrical energy storage device throughout the interchange process.

[0004] Hence, there is a need in the art for solutions which will overcome the above mentioned drawback(s), among others.OBJECTS

[0005] The principal object of embodiments herein is to disclose a locking and unlocking mechanism for an electrical energy storage device handling system (BHS).

[0006] Another object of embodiments herein is to disclose a locking and unlocking mechanism for an electrical energy storage device handling system that ensures a secure attachment of the electrical energy storage device to the BHS.

[0007] Another object of embodiments herein is to disclose a locking and unlocking mechanism for an electrical energy storage device handling system that provides stability to the electrical energy storage device during interchange operation.

[0008] Another object of embodiments herein is to disclose a locking and unlocking mechanism for an electrical energy storage device handling system that ensures the safe locking and unlocking of the electrical energy storage device from a dock in a vehicle or charging and interchange station.

[0009] Another object of embodiments herein is to disclose a locking and unlocking mechanism for an electrical energy storage device handling system that maintains reliability under various operating conditions.

[0010] Another object of embodiments herein is to disclose a locking and unlocking mechanism for an electrical energy storage device handling system that is easy to operate and maintain.

[0011] 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 modificationsSUMMARY

[0012] An electrical energy storage device handling system comprises a loading platform configured to accommodate at least one cassette, and a control unit provided on the platform to push or pull the cassette(s) for interchange. A prime mover coupled to the control unit provides linear movement using a rack and pinion mechanism. The control unit is alsoequipped with a locking and unlocking mechanism, a key, and a switch arm that is configured to rotate.

[0013] The key is operated by a two-way servo motor present on the control unit, and the switch arm is mounted on the shaft of this servo motor to rotate accordingly. The key is substantially cylindrical and mounted off-centre on the shaft, allowing it to trace an elliptical path during rotation. In some configurations, the key may be shaped like an egg or an ellipse, and the switch arm may have a ‘T’ shape.

[0014] Additionally, the electrical energy storage device handling system includes a left side (LS) limit switch and a right side (RS) limit switch, both of which pause the system's operation when engaged. The LS limit switch is mounted on the left side and the RS limit switch on the right side of the control unit, positioned substantially opposite each other. The switch arm is designed to engage both limit switches during the locking and unlocking operations involving the dock of a vehicle or a charging and interchange station.

[0015] In the unlock position, the key engages the LS limit switch. Upon insertion of the key into the cassette, the control unit rotates the servo motor shaft in the direction opposite to the LS limit switch. The switch arm rotates in tandem with the shaft, and after a 180-degree rotation, the switch arm engages the RS limit switch, halting further rotation and securing the key in a locked position. In this state, the key disengages the cassette from the dock. The control unit, aided by the prime mover, then pulls the cassette onto the loading platform. During unloading, the cassette is pushed into the dock, and the servo motor is rotated in the opposite direction. This action causes the switch arm to disengage the RS limit switch and complete another 180-degree rotation until it engages the LS limit switch again, preventing further motion. At this point, the key is in the unlocked state, securing the cassette to the dock.

[0016] The loading platform may be designed to hold multiple cassettes. The control unit also includes a processor for managing the locking and unlocking operations. Additionally, the system features sensors for detecting the position of the cassette during loading and unloading. The system features a user interface to allow manual control over the locking and unlocking process.BRIEF DESCRIPTION OF FIGURES

[0017] 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 tothe following illustrative drawings. Embodiments herein are illustrated by way of examples in the accompanying drawings, in which:

[0018] FIG. 1 illustrates an isometric view of an isometric view of Electrical energy storage device handling system, according to embodiments as disclosed herein;

[0019] FIG. 2 illustrates a front view of a locking and unlocking mechanism for an electrical energy storage device handling system in lock condition, according to embodiments as disclosed herein; and

[0020] FIG. 3 illustrates a front view of a locking and unlocking mechanism for an electrical energy storage device handling system in unlock condition, according to embodiments as disclosed herein.DETAILED DESCRIPTION

[0021] 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.

[0022] 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.

[0023] 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.

[0024] 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 other functions 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.

[0025] 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.

[0026] 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 areparticularly 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.

[0027] The embodiments herein achieve a locking and unlocking mechanism for an electrical energy storage device handling system. Referring now to the drawings, and more particularly to FIGS. 1 through 3, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.

[0028] The following terms and reference numerals have been referred to herein:100 - Electrical energy storage device Handling System102 - Interchange Platform104 - Prime Mover106 - Control Unit110 - Lock And Unlock Mechanism112 - Key114 - Switch Arm116 - LS Limit Switch118 - RS Limit Switch

[0029] FIGs. 1-3 illustrates a locking and unlocking mechanism 110 for an electrical energy storage device handling system (BHS) 100. The system 100 comprises at least one loading platform 102, a prime mover 104, and a control unit 106. The loading platform 102 is configured to accommodate at least one cassette containing an electrical energy storage device. The control unit 106 is mounted on the loading platform 102 and is configured to push and pull the cassette for interchange operations. The prime mover 104 is coupled to the control unit 106 and provides linear movement to the control unit 106 through a rack and pinion arrangement.

[0030] The loading platform 102 serves as the base structure of the electrical energy storage device handling system 100. The loading platform 102 can provide a stable and secure surface for accommodating the cassette containing the electrical energy storage device. The loading platform 102 may be constructed from durable materials (such as, but not limited to, steel, aluminium alloys, and so on) to withstand the weight and frequent movement of thecassettes. In alternative embodiments, the loading platform 102 may incorporate adjustable features (such as, but not limited to, a wider platform, and so on) to accommodate cassettes of various sizes or shapes.

[0031] The prime mover 104 can generate the motive force required for the linear movement of the control unit 106. The prime mover 104 may be at least one of an electric motor, a hydraulic actuator, or a pneumatic system, depending on the specific requirements of the application. In an embodiment herein, the prime mover 104 may be a servo motor with position control capabilities. Alternatively, a stepper motor could be used for applications requiring incremental movements. The prime mover 104 is coupled to the control unit 106 through a rack and pinion arrangement, which converts the rotational motion of the prime mover into linear motion.

[0032] The control unit 106 is mounted on the loading platform 102 and serves as the primary interface for manipulating the cassette. The control unit 106 can push and pull the cassette during interchange operations. The control unit 106 may incorporate sensors (such as, but not limited to, a proximity sensor, a photoelectric sensor, an ultrasonic sensor, a magnetic sensor, a laser sensor, and so on) and feedback mechanisms to ensure accurate positioning and control of the cassette. In an embodiment herein, the control unit 106 may include a locking mechanism to secure the cassette during movement. Alternative designs of the control unit 106 may feature different attachment mechanisms or gripping systems to accommodate various cassette designs.

[0033] The rack and pinion arrangement connecting the prime mover 104 to the control unit 106 comprises of a linear gear rack attached to the control unit 106 and a pinion gear driven by the prime mover 104. As the pinion gear rotates, the pinion gear engages with the teeth of the rack, converting rotational motion into linear motion. This mechanism provides precise control over the position and movement of the control unit 106. In alternative embodiments, other linear motion systems (such as, but not limited to, ball screws or linear actuators) could be used in place of the rack and pinion arrangement.

[0034] The lock and unlock mechanism 110 is provided on the control unit 106. The lock and unlock mechanism 110 can be used for securing and releasing the cassette during interchange operations. The lock and unlock mechanism 110 includes a key 112, which can be operated by a two-way servo motor present on the control unit 106. The key 112 can be substantially cylindrical in shape and is mounted on the shaft of the servo motor at an offsetwith the centre of the key 112. The offset positioning of the key 122 traces an elliptical path during rotation. This design feature can be used for lifting the cassette lock during the detachment of the electrical energy storage device during interchange.

[0035] The cylindrical shape of the key 122 allows for smooth insertion and rotation within the cassette's locking mechanism. The offset mounting of the key 112 on the servo motor shaft creates an eccentric motion during rotation. This eccentric motion enables engaging and disengaging of the cassette lock effectively. In an alternative embodiment, the key 112 may be shaped in the form of an egg or ellipse to further optimize the locking and unlocking process.

[0036] A left side (LS) limit switch 116 is mounted on the left side of the control unit 106. The LS limit switch 116 can be used to pause the operation of the servo motor when engaged. The LS limit switch 116 serves as a safety mechanism to prevent over -travel of the key 112 in the unlocked position. In alternative embodiments, the LS limit switch 116 could be replaced with other types of sensors (such as, but not limited to, optical sensors, magnetic sensors, and so on) to achieve the same functionality.

[0037] A Right side (RS) limit switch 118 is mounted on the right side of the control unit 106 in line and substantially opposite to the LS limit switch 116. Similar to the LS limit switch, the RS limit switch 118 is configured to pause the operation of the servo motor when engaged. This switch acts as a safety stop for the key 112 in the locked position. Alternative designs may incorporate adjustable limit switches to accommodate different cassette designs or locking mechanisms.

[0038] A switch arm 114 having a substantially ‘T’ shape is mounted on a shaft of the two-way servo motor (which is present on the control unit 106) and is configured to rotate along the shaft. The switch arm 114 is configured to engage the LS limit switch 116 and the RS limit switch 118 during the locking and unlocking of the cassette from a dock, wherein the dock can be present in either of a vehicle or a charging and interchange station. The 'T' shape of the switch arm 114 allows for precise and reliable activation of the limit switches. In alternative embodiments, the switch arm 114 could be designed with different shapes or multiple arms to interact with additional sensors or switches for enhanced control and safety features.

[0039] In the cassette loading operation, the control unit 106 positions the key 112 in the unlock position, thereby engaging the LS Limit switch 116. Upon insertion of the key 112 into the cassette, the control unit 106 operates the servo motor to rotate the key 112 in adirection opposite to the LS limit switch 116. As the servo motor's shaft rotates, the switch arm 114 also rotates in tandem. After a 180-degree rotation of the shaft, the switch arm 114 engages the RS limit switch 118, thereby halting the shaft's rotation and securing the key 112 in the locked position. In this locked state, the key 112 disengages the cassette from the dock and secures it to the key 112. The control unit 106, assisted by the prime mover 104, pulls the cassette out of the dock onto the loading platform 102.

[0040] During unloading, the control unit 106 pushes the cassette into the dock. Subsequently, the control unit 106 initiates the servo motor to rotate in the opposite direction from the locked position. As a result, the switch arm 114 disengages the RS limit switch 118, prompting a 180-degree rotation of the shaft, which then engages the LS limit switch 116, preventing further shaft rotation. At this point, the key 112 is in the unlocked state, and the cassette is secured to the dock.

[0041] The electrical energy storage device handling system 100 provides an efficient and automated solution for interchanging electrical energy storage devices, such as batteries, in various applications including electric vehicles and renewable energy storage systems. The locking and unlocking mechanism 110 provides a reliable and efficient means of securing and releasing electrical energy storage devices in a handling system. Its design allows for precise control over the locking and unlocking processes, ensuring safe and consistent operation in various applications such as electric vehicle battery swapping stations or industrial energy storage facilities.

[0042] 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 electrical energy storage device handling system comprising: a loading platform (102) configured to accommodate at least one cassette; a control unit (106) provided on the loading platform (102) and configured to push-pull the at least one cassette for interchange; a prime mover (104) coupled to the control unit (106) to provide linear movement through a rack and pinion arrangement; a locking and unlocking mechanism (110) provided on the control unit (106); a key (112) provided on the control unit (106); a switch arm (114) configured to rotate; and a left side (LS) limit switch (116) and a right side (RS) limit switch (118) mounted on the control unit (106) and configured to pause operation when engaged.

2. The electrical energy storage device handling system as claimed in claim 1, wherein the key (112) is operated by a two-way servo motor present on the control unit (106), wherein the switch arm (114) is mounted on a shaft of the two-way servo motor and configured to rotate along the shaft.

3. The electrical energy storage device handling system as claimed in claim 2, wherein the key (112) is substantially cylindrical shaped and mounted on the shaft of the servo motor at an offset with the centre of the key (112), wherein the offset positioning of the key (112) traces an elliptical path during rotation.

4. The electrical energy storage device handling system as claimed in claim 1, wherein the key (112) is shaped in the form of one of an egg, or an ellipse.

5. The electrical energy storage device handling system as claimed in claim 1, wherein the switch arm (114) has a substantially 'T' shape.

6. The electrical energy storage device handling system as claimed in claim 1, wherein the LS limit switch (116) is mounted on the left side of the control unit (106) and the RS limit switch (118) is mounted on the right side of the control unit (106) in line and substantially opposite to the LS limit switch (116).

7. The electrical energy storage device handling system as claimed in claim 1, wherein the switch arm (114) is configured to engage the LS limit switch (116) and the RS limit switch (118) during locking and unlocking of the at least one cassette from a dock.

8. The electrical energy storage device handling system as claimed in claim 1, wherein the key (112) is in an unlock position when engaging the LS limit switch (116).

9. The electrical energy storage device handling system as claimed in claim 2, wherein the control unit (106) is configured to operate the servo motor to rotate the key (112) in a direction opposite to the LS limit switch (116) upon insertion of the key (112) into the at least one cassette.

10. The electrical energy storage device handling system as claimed in claim 9, wherein the switch arm (114) rotates in tandem with a shaft of the servo motor, wherein after a 180- degree rotation of the shaft, the switch arm (114) engages the RS limit switch (118), thereby halting the shaft's rotation and securing the key (112) in a locked position, wherein in the locked position, the key (112) disengages the at least one cassette from the dock and secures it to the key (112).

11. The electrical energy storage device handling system as claimed in claim 10, wherein the control unit (106) is configured to pull the at least one cassette out of the dock onto the loading platform (102) assisted by the prime mover (104).

12. The electrical energy storage device handling system as claimed in claim 1, wherein during unloading, the at least one cassette is first pushed into the dock.

13. The electrical energy storage device handling system as claimed in claim 12, wherein during unloading, the control unit (106) is configured to rotate the servo motor in a direction opposite to the locked position.

14. The electrical energy storage device handling system as claimed in claim 13, wherein the switch arm (114) disengages the RS limit switch (118), prompting a 180-degree rotation of the shaft, wherein the shaft engages the LS limit switch (116), preventing further shaft rotation.

15. The electrical energy storage device handling system as claimed in claim 1, wherein the system includes at least one sensor for detecting the position of the at least one cassette during loading and unloading operations.

16. The electrical energy storage device handling system as claimed in claim 1, wherein the system includes a user interface for manual control of the locking and unlocking operations.

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