Systems and methods for managing racks in a charging and interchange station

Abstract

The present disclosure relates to a Rack Management System (RMS) 100 for efficiently managing battery charging and swapping in an interchange stations. A Rack Supervising Unit (RSU) 105 oversees battery identification, charging, thermal management, and fault detection. The RMS 100 enables real-time data logging, communication 155, 165, and safety measures, ensuring operational efficiency. The RMS 100 automates charging supervision, enhances battery life, and optimizes energy utilization. Additionally, the RMS 100 detects anomalies and prevents unauthorized battery use, making it scalable for future advancements.

Description

Systems and methods for managing racks in a charging and interchange stationCROSS REFERENCE TO RELATED APPLICATIONThis application is based on and derives the benefit of Indian Provisional Application IN202541028166, the contents of which are incorporated herein by reference.TECHNICAL FIELD

[0001] Embodiments disclosed herein relate to charging and interchange stations, and more particularly to systems and methods for managing one or more racks in a charging and interchange station.BACKGROUND

[0002] The shift toward electric vehicles (EVs) is driven by the urgent need to reduce carbon emissions and transition to sustainable transportation. However, the widespread adoption of EVs faces significant challenges, particularly in terms of charging infrastructure and battery management. Traditional charging methods, which require long waiting times and limited range, have highlighted the need for innovative solutions like battery interchange technology. Battery charging and interchange stations, where depleted EV batteries are quickly replaced with fully charged batteries, offer a promising alternative to conventional charging. However, the success of these stations depends heavily on efficient management systems to handle the complex processes of battery charging, storage, and interchange. Without proper management, these stations could face operational inefficiencies, safety risks, and user dissatisfaction, ultimately hindering the growth of the EV ecosystem.

[0003] Efficient management of battery charging and interchange stations is critical to ensuring optimal performance and longevity of EV batteries. Lithium-ion batteries, which are commonly used in EVs, are sensitive to factors, such as, but not limited to, charging rates, temperature, state of charge, and so on. Poor management can lead to overcharging, overheating, or uneven charging, all of which accelerate battery degradation and reduce their lifespan. A charging and interchange station employs battery management systems (BMS) to monitor and control these factors in real time, ensuring that batteries are charged under optimal conditions. This not only extends the life of the batteries, but also enhances their reliability and performance, providing EV users with a seamless and dependable experience. Furthermore, efficient management systems can integrate renewable energy sources, such as solar or windpower, to charge batteries sustainably, aligning with the broader goals of reducing carbon footprints.

[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 systems and methods for managing racks in a charging and interchange station, that optimizes battery charging efficiency, ensuring a steady supply of fully charged batteries while preventing overcharging and degradation of the batteries.

[0006] Another object of embodiments herein is to disclose systems and methods for managing racks in a charging and interchange station that dynamically allocates batteries based on real-time demand, vehicle compatibility, and usage patterns to prevent shortages and delays.

[0007] Another object of embodiments herein is to disclose systems and methods for managing racks in a charging and interchange station that integrates smart racking and monitoring to maintain an accurate inventory of charged, depleted, and in-use batteries.

[0008] Another object of embodiments herein is to disclose systems and methods for managing racks in a charging and interchange station that enhances operational efficiency by reducing vehicle wait times through automated scheduling, and priority -based interchange.

[0009] Another object of embodiments herein is to disclose systems and methods for managing racks in a charging and interchange station that ensures the safety and reliability of battery handling, storage, and interchange processes through advanced thermal management and fault detection.

[0010] Another object of embodiments herein is to disclose systems and methods for managing racks in a charging and interchange station that utilizes predictive analytics and Artificial Intelligence (Al)-driven demand forecasting to optimize battery availability, and minimize downtime.

[0011] Another object of embodiments herein is to disclose systems and methods for managing racks in a charging and interchange station that prevents unauthorized batteiy interchange and ensures secure transactions through authentication and access control mechanisms.

[0012] Another object of embodiments herein is to disclose systems and methods for managing racks in a charging and interchange station that supports seamless integration with a digital platform for remote monitoring, data analysis, and user management.

[0013] Another object of embodiments herein is to disclose systems and methods for managing racks in a charging and interchange station that minimizes operational costs by optimizing energy consumption, reducing idle battery time, and enhancing battery lifecycle management.

[0014] Another object of embodiments herein is to disclose systems and methods for managing racks in a charging and interchange station that ensures compliance with regulatory standards and environmental guidelines for safe battery disposal and recycling.

[0015] 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.BRIEF DESCRIPTION OF FIGURES

[0016] 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 illustratory drawings. Embodiments herein are illustrated by way of examples in the accompanying drawings, and in which:

[0017] FIG. 1 illustrates a system of managing charging and interchange stations, according to embodiments as disclosed herein; and

[0018] FIG.2 illustrates a flowchart of a method of managing charging and interchange stations, according to embodiments as disclosed herein.DETAILED DESCRIPTION

[0019] 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 to not 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.

[0020] For the purposes of interpreting this specification, the definitions (as defined herein) will apply and whenever appropriate the terms used in 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 .

[0021] 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.

[0022] 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 analog 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.

[0023] 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 of 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.

[0024] 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.

[0025] The embodiments herein achieve systems and methods for managing racks in a charging and interchange station, that optimizes battery charging efficiency, ensuring a steady supply of fully charged batteries while preventing overcharging and degradation of the batteries. Referring now to the drawings, and more particularly to FIGS. 1 through 2, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.

[0026] The following terms / modules / components / systems and corresponding reference numerals have been referred to herein:100 - Rack Management System (RMS)105 - Rack Supervising Unit (RSU)110 - Temperature, pressure and Humidity (TPH) sensor115 - Energy Meter120 -Data Logger122 - Temperature Sensor125 - Communication protocol Controller (for example, RS485 OE)127 - Communication protocol (for example, RS485)130 - Communication Switch135 - Input / Output manager136 -Pump / valves137 - Sensors138 - Relays140 - Compartment142 - Charge Controller (CC)143 -Communication Controller (OE)145 - Battery Pack147 - A first Control Area Network (CAN-C)148 - A second Control Area Network (CAN-T)150 - Master control unit (MCU)155 - Communication Protocol (TCP / IP)160 - Input / output channel165 - Wireless network

[0027] Embodiments herein disclose systems and methods for managing racks in a charging and interchange station that enables automated monitoring and management of racks within the charging and swapping station, ensuring efficient operations.

[0028] Battery interchange technology involves replacing a depleted battery with a fully charged one at specialized battery charging and interchange stations (herein after referred to as station, charging and interchange stations, and so on). To streamline station operations,these stations are typically equipped with one or more racks, wherein each rack contains one or more compartments designed to hold battery packs for charging and distribution. Each rack includes a thermal management system to regulate the temperature of the batteries within the compartment(s). Additionally, every compartment is outfitted with at least one charging unit, which includes one or more charging connectors, and rectifiers to facilitate the charging of batteries that require charging. Moreover, each rack is equipped with a variety of sensors and safety mechanisms to ensure the secure handling of batteries and the overall safety of the station.

[0029] For optimal and efficient management of the rack, a Rack Management System (RMS) 100 is provided, wherein the RMS 100 can oversee, monitor, and control various components essential for seamless operation. The RMS 100 comprises a Rack Supervising Unit (RSU) 105, wherein theRSU 105 can manage the rack components, thereby ensuring optimal performance, and facilitating smooth communication between the battery interchange infrastructure and external networks. To maintain a safe and controlled environment, the system incorporates a Temperature, Pressure, and Humidity (TPH) sensor 110, wherein the TPH sensor 110 continuously tracks environmental conditions within the rack to prevent overheating, moisture buildup, or pressure variations that could affect performance. The system further includes a temperature sensor 122, wherein the temperature sensor 122 provides precise thermal monitoring in the station (including the racks, compartments, and so on), allowing for early detection of any abnormal fluctuations that may pose risks to the safety of the battery and / or the station.

[0030] The RMS 100 can comprise an energy meter 115, wherein the energy meter 115 can measure the power consumption of the station (including the components in and / or connected to the station, the rack, the compartments, and so on), aiding in efficient distribution and monitoring of energy usage.

[0031] The RMS 100 can comprise a datalogger 120, wherein the datalogger 120 can collect and store real-time operational datafrom various sensors and components in the station, enabling historical analysis and system diagnostics for predictive maintenance and performance optimization. Communication and data exchange within the RMS 100 is handled through one or more interfaces (for example, the communication protocol controller (for example, RS485 OE) 125, the communication protocol (for example, RS485) 127, Controller Area Networks (CANs) 147, 148, wireless network(s) 160, and so on), which facilitate robust and noise-resistant communication for data transmission within industrial automationenvironments. The RMS 100 can further comprise a communication switch 130, wherein the communication switch 130 can ensure seamless dataflow by managing network traffic within the station, directing data packets efficiently between components and external monitoring systems.

[0032] To support input and output operations, the RMS 100 includes a plurality of Input / Output managers 135. The Input / Output managers 135 can provide essential connectivity for handling digital and analogue signals, enabling effective control and monitoring of various rack functions (such as, but not limited to, sensor feedback, alarm triggers, power management, and so on). Charging operations within the rack can be regulated by a Charge Controller (CC) 142. The CC 142 can optimize the charging and discharging of batteries to maintain efficiency and ensure battery longevity. For seamless integration and coordination between batteiy modules, charge controllers, and other rack components, a Communication Controller 143 can facilitate high-speed datatransfer via a network interface (for example, a Control AreaNetwork (CAN), a Local Interconnect Network (LIN), and so on). Within this framework, a first Control Area Network 147 (CAN-C) can transmit data relating to charge controllers 142 to and from the respective battery packs 145. A second Control AreaNetwork 148 (CAN-T) can focus on tracking and transmitting critical battery and rack status data between the respective battery packs 145 and the communication controller 143.

[0033] To ensure reliable communication beyond the rack (with other components / modules / systems in the charging and interchange station and / or an external entity), the RMS 100 includes at least one communication protocol (for example, TCP / IP) 155 enabling secure data exchange over the internet for remote monitoring and control; for example, the communication protocol 155 can be used for enabling communication between the communication switch 130 and the charge controller 142, the communication protocol 155 can be used for enabling communication between the communication switch 130 and the communication controller 143, and so on. The Input / Output channel 160 serves as an interface, connecting sensors, controllers, and external devices to facilitate seamless data acquisition and operational adjustments; for example, the Input / Output channel 160 can be used for enabling the Input / Output manager 135 and one or more components (for example, pump(s) / valve(s) 136, sensor(s)137, relay(s) 138, and soon). Finally, the wireless network 165 provides a remote communication link, allowing real-time monitoring, diagnostics, and system updates without the need for physical connectivity; for example, between the battery packs 145 and a master control unit (MCU) 150. Together, these components form a highly integrated RMS 100,ensuring intelligent, efficient, and safe operation of battery interchange infrastructure while enabling real-time communication, monitoring, and control for enhanced reliability and performance.

[0034] FIG. 1 illustrates the Rack Management System 100. The RMS 100 can efficiently monitor, control, and manage the operations within a battery -interchange infrastructure. The Rack Supervising Unit (RSU) 105 serves as the primary control hub. The RSU 105 ensures seamless communication and coordination among the various components of the charging and interchange station. The system 100 integrates the Temperature, Pressure, and Humidity (TPH) sensor 110, which can be used to maintain optimal environmental conditions within the rack. The TPH sensor 110 continuously monitors the internal atmosphere of the rack, and reports the internal atmosphere to the RSU to prevent overheating or moisture -related issues. The temperature sensor 122 provides precise thermal monitoring for the safe operation of batteries and electronic components. The energy meter 115 can manage the energy within the rack. The energy meter 115 can accurately measure the power consumption, and report themeasured power consumption to the RSU 105 for further processing. The datalogger 120 records real-time operational data for performance analysis and predictive maintenance. The sensors and datalogger units communicate with the RSU 105 through the communication protocol 127 (such as, but not limited to, RS485), as managed by the communication protocol controller 125 (RS485 OE). The communication protocol 127 and controller 125 ensure a reliable and structured data flow within the RMS 100.

[0035] Additionally, the Input / Output manager 135 manages various actuators and system interfaces, and can control various components / modules / systems present in the charging and interchange station (such as, but not limited to, controlling pumps / valves 136, sensors 137, and relays 138) through input / output channels 160 and reports to the RSU 105. These components regulate fluid flow, temperature management, and system automation necessary for efficient battery charging and interchange processes based on the instructions provided by the RSU 105.

[0036] Battery charging and control of the battery packs placed within the compartments 140 are handled by the RSU 105 through the Charge Controller 142. The charge controller 142 ensures the optimal charging and discharging of battery packs. The charge controller 142 interacts with the battery pack 145 through the Control Area Network (CAN -C) 147, which monitors and controls charging operations.

[0037] To maintain seamless communication between battery management systems, the communication controller 143 (CAN OE) facilitates high-speed data transfer through the Control AreaNetwork(CAN-T) 148, which transmits battery status data. The battery pack 145, housed within the compartment further interacts with a Master Control Unit (MCU) 150 through a wireless network 165, ensuring synchronized operation across multiple racks and battery interchange stations.

[0038] For effective communication and network management, the communication switch 130 acts as a central node, routing data between different subsystems such as the communication protocol controller 125, the input / output manager 135, the charge controller 142 and the communication controller 143 using at least one communication protocol 155 (such as, but not limited to, Transmission Control Protocol / Intemet Protocol (TCP / IP), and so on). The communication protocol 155 enables secure and structured data transfer to / from the RSU 105 allowing the RMS 100 to integrate with broader networked systems. Further, the communication protocol 155 also links the RSU 105 to the MCU 150, enabling real time monitoring and control of operations.

[0039] The MCU 150 can be a higher-level control unit, overseeing multiple racks in the charging and interchange station, and ensuring smooth battery interchange operations. The RMS 100 can effectively manage battery performance, optimize energy distribution, maintain safety protocols, and provide seamless communication between the rack infrastructure, and external control units.

[0040] The RMS 100 can efficiently oversee the charging, monitoring, and management of battery packs within the charging and interchange station. On a battery pack 145 being inserted into a designated compartment 140, the RSU 105 initiates a series of automated operations. The RSU 105 determines whether charging can commence based on the battery’s status through the charge controller (CC) 142 and the CAN-T 147. Once validated, the energy meter 115 can begin capturing charging data while the communication switch 130 facilitates seamless data exchange between the various components. During charging, the RSU 105 can continuously monitor critical parameters (such as, but not limited to, cell voltage deviations, charger voltage and current levels, charger temperature, and so on) to prevent overcharging, overheating, or electrical failures. If any abnormalities are detected (i.e., at least one abnormal parameter exceeds at least one corresponding predefined threshold; for example, cell voltage deviation, temperature rise, leakage detection, communication fault(s), and so on), the RSU 105 initiates quarantine measures to isolate faulty battery pack(s), ensuring the safetyand reliability of the charging process. The RSU 105 can disable charging and discharging of isolated battery pack(s) by transmitting a control command to the charge controller 142 over the CAN-C 147 to electrically isolate the battery pack 145. The RSU 105 can further flag the corresponding compartment 140 as unavailable in the system database and prevent swap authorization until the battery pack 145 is cleared by an operator (for example, through diagnostic evaluation). Additionally, charge records are generated, and indications of the charging process are displayed.

[0041] In an embodiment herein, bidirectional power flow (B2G) may be provided to allow energy to be fed back to the grid. In an embodiment herein, the charge controller 142 can enable bidirectional power flow, wherein the charge controller 142 can be a bidirectional power conversion unit capable of operating in both grid-to-battery (G2B) and battery -to-grid (B2G) modes. The RSU 105 can control the operating mode by transmitting control commands via the CAN-C 147 network based on battery state of charge, grid demand signals, and station energy management policies. In the B2G mode, stored energy from the battery pack 145 is supplied back to the grid through the charge controller 142 and associated power electronics interface connected to the station power bus.

[0042] Simultaneously, the RSU 105 communicates with the battery pack through the CAN Communication Controller 143 (CAN OE) and the CAN-T 148 to provide real-time updates on battery health. The system performs a capacity check using bidirectional communication, ensuring the battery is within operational parameters. The RSU 105 also detects and manages battery faults and swap connector leakage, which could cause energy losses or safety hazards. Furthermore, the system supports multi-mode switching, enabling dynamic energy transfer between battery -to-battery (B2B), battery -to-grid (B2G), and grid-to-battery (G2B) charging. Through charger-to-dock mapping, embodiments herein ensure that each battery is placed in the correct dock, preventing mismatches and optimizing performance.

[0043] The RSU 105 can also perform thermal management, ensuring batteries remain within optimal temperature ranges. The RSU 105 can control additional components / modules (for example, pumps, chillers, radiator fans, and so on (not shown)) via pumps / valves 136, sensors 137, and relays 138, preventing overheating and thermal stress. The RSU 105 can continuously monitor temperature differentials (AT) within and across battery packs 145, and can update a thermal database (not shown) with the monitored temperature differentials for precise control. Additionally, environmental conditions (for example, temperature, humidity,and so on) are tracked using the TPH sensor 110, further enhancing operational safety and efficiency.

[0044] The RSU 105 can also perform rack-level management and communication. The RSU 105 can log energy records for each dock, evaluates dock efficiency, and manage power-up and power-down sequences, including self-tests and low-power mode operations. The RMS 100 can include one or more active safety measures (such as, but not limited to, emergency and smoke monitoring) to prevent hazardous situations. The RSU 105 can send periodic updates on rack status, live RSU data, energy consumption, and battery health to the MCU 150 using the communication protocol 155. Further, the MCU 150 can also communicate with the battery pack 145 through the wireless network 165 (such as, but not limited to, Wi-Fi), ensuring seamless remote monitoring and control.

[0045] Once charging is complete, the CC 142 can verify that the battery has reached the optimal charge level before making it available for vehicle deployment or standby storage. The CC 142 can update the inventory records / database (not shown). The CC 142 can further reset the compartment 140, thereby preparing the dock for the next cycle. With its intelligent charge supervision, real-time battery monitoring, advanced thermal management, and seamless communication, the RMS 100 ensures a safe, reliable, and automated battery interchange process, optimizing efficiency and enhancing the overall functionality of the batteiy interchange stations.

[0046] FIG. 2 is a flowchart depicting the process of managing charging and interchange stations. In step 201, the RMS 100 determines that a battery pack has been inserted into the station, based on inputs from the sensors 137 (via the Input / Output channel 160) and the charge controller 142 (via the Input / Output channel 160). In step 202, the RMS 100 verifies the authenticity and status of the battery pack by communicating with a BMS (not shown) through the communication controller 143. In step 203, the RMS 100 maps the inserted batteiy pack to the respective rack that it has been inserted into, thereby ensuring proper allocation and tracking. On successfully verifying the battery compatibility and safety, in step 204, the RMS 100 initiates the charging process by enabling the charge controller 142. When the charging is ongoing, in step 205, the RMS 100 monitors one or more charging parameters (for example, voltage, current, temperature, and so on) through the energy meter 115, and the TPH sensor 110. In step 206, the RMS 100 manages thermal conditions in the station using the pumps / valves 136, radiator fan(s), chillers, condensers, and so on, thereby ensuring safe battery temperature regulation. In step 207, the RMS 100 records and updates the charge data usingthe data logger 120, thereby maintaining energy consumption records for efficiency analysis. In step 208, the RMS 100 communicates periodic status updates to the MCU 150 via the TCP / IP communication protocol 155, thereby enabling the MCU 105 to perform remote monitoring. In step 209, the RMS 100 completes the charging cycle and verifies the readiness of the battery pack 145 by checking charge completion indicators and ensuring that the batteiy pack 145 is ready for interchanging. In step 210, the RMS 100 enables removal of the ready battery pack 145, authorizes the swap, and updates the system records, before allowing the battery to be interchanged. The various actions in method 200 may be performed in the order presented, in a different order or simultaneously. Further, in some embodiments, some actions listed in FIG. 2 may be omitted.

[0047] Embodiments herein offer several technical advancements, including, but not limited to, systems and methods for managing charging and interchange stations:- that enables automated monitoring and management of battery packs within the charging and interchange stations, ensuring efficient operations;- that prevents the use of faulty or unauthorized batteries by implementing quarantine management, enhancing safety and reliability;- that facilitates bidirectional power flow (B2B, B2G, G2B), optimizing energy utilization and allowing grid integration for improved energy efficiency;- that continuously tracks and records energy consumption for each dock, enabling precise energy auditing and operational analytics;- that ensures real-time monitoring of battery parameters, including voltage, current, temperature, and connector integrity, preventing potential failures;- that incorporates advanced thermal management through controlled pumps, chillers, and radiator fans, preventing battery overheating and extending lifespan;- that enhances operational safety with emergency detection features such as smoke monitoring and active fault handling mechanisms;- that enables seamless communication with a Master Control Unit (MCU) via periodic status updates, improving remote monitoring and control capabilities;- that optimizes compartment utilization through charger-to-dock mapping, ensuring accurate placement and minimizing logistical errors; and- that improves system scalability by allowing integration with future advancements, such as Al-driven predictive maintenance and adaptive energy distribution.

[0048] 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 device and software module.

[0049] The embodiments disclosed herein describe systems and methods for managing racks in a charging and interchange station, that optimizes battery charging efficiency, ensuring a steady supply of fully charged batteries while preventing overcharging and degradation of the batteries. 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 like 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.

[0050] 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 practised with modification within the scope of the embodiments as described herein.

Claims

STATEMENT OF CLAIMSWe claim:

1. A method (200) for managing at least one rack in a charging and interchange station, the method comprising:determining (201), by a Rack Management System (RMS) (100), that a battery pack has been inserted into a rack in the charging and interchange station, based on inputs from a plurality of sensors (137), via an Input / Output channel (160) and a charge controller (142), via the Input / Output channel (160);verifying (202), by the RMS (100), authenticity and status of the battery pack by communicating with a Battery Management System (BMS) through a communication controller (1 3);mapping (203), by the RMS (100), the inserted battery pack to the rack that it has been inserted into;initiating (204), by the RMS (100), charging process for the battery pack by enabling the charge controller (142), on successfully verifying compatibility and safety of the battery pack; completing (209), by the RMS (100), charging cycle and verifying readiness of the battery pack by checking charge completion indicators and ensuring that the battery pack is ready for interchanging; andenabling (210), by the RMS (100), removal of the battery pack, authorizing the interchange, and updating the system records.

2. The method, as claimed in claim 1, wherein the method comprises monitoring (205), by the RMS (100), one or more charging parameters through an energy meter (115), and a Temperature, pressure and Humidity (TPH) sensor (110).

3. The method, as claimed in claim 1, wherein the method comprises managing (206), by the RMS (100), thermal conditions in the station using a plurality of pumps / valves (136), at least one radiator fan, at least one chillers, and at least one condenser.

4. The method, as claimed in claim 1, wherein the method comprises:recording and updating (207), by the RMS (100), charge data using adata logger (120); andcommunicating (208), by the RMS (100), periodic status updates to a Master Control Unit (MCU) (150) using a Transmission Control Protocol / Intemet Protocol (TCP / IP) communication protocol (155).

5. The method, as claimed in claim 1, wherein the method comprises initiating, by the RMS (100), at least one quarantine measure to isolate at least one faulty battery pack, wherein isolating the at least one faulty battery pack comprises:disabling, by the RMS (100), charging and discharging of the at least one faulty battery pack by transmitting a control command to the charge controller (142) over a first Control Area Network (CAN-C) (1 7);flagging, by the RMS (100), a compartment (140) containing the at least one faulty battery pack; andpreventing, by theRMS (100), swapping authorization of the atleast one faulty battery pack.

6. The method, as claimed in claim 1, wherein the method comprises providing, by the RMS (100), bidirectional power flow to allow energy to be fed back to a grid connected to the charging and interchange station, based on state of charge of the battery pack, grid demand signals, and energy management policies of the charging and interchange station.

7. A Rack Management System (RMS) (100) for managing at least one rack in a charging and interchange station, the method comprising:a plurality of sensors (137);an Input / Output channel (160);a charge controller (142);a communication controller (143);wherein the RMS (100) is configured to:determine that a battery pack has been inserted into a rack in the charging and interchange station, based on inputs from the plurality of sensors (137), via the Input / Output channel (160) and a charge controller (142), via the Input / Output channel (160); verify authenticity and status of the battery pack by communicating with a Battery Management System (BMS) through the communication controller (143);map the inserted battery pack to the rack that it has been inserted into;initiate charging process for the battery pack by enabling the charge controller (142), on successfully verifying compatibility and safety of the battery pack;complete charging cycle and verifying readiness of the battery pack by checking charge completion indicators and ensuring that the battery pack is ready for interchanging; and enable removal of the battery pack, authorizing the interchange, and updating the system records.

8. The Rack Management System (RMS), as claimed in claim 7, wherein the RMS (100) comprises an energy meter (115), and a Temperature, pressure and Humidity (TPH) sensor (110), wherein the RMS (100) is configured to monitor one or more charging parameters through the energy meter (115), and the TPH sensor (110).

9. The Rack Management System (RMS), as claimed in claim 7, wherein the RMS (100) comprises a plurality of pumps / valves (136), at least one radiator fan, at least one chillers, and at least one condenser, wherein the RMS (100) is configured to manage thermal conditions in the station using the plurality of pumps / valves (136), the at least one radiator fan, the at least one chillers, and the at least one condenser.

10. The Rack Management System (RMS), as claimed in claim 7, wherein the RMS (100) comprises a data logger (120), and a Master Control Unit (MCU) (150) wherein the RMS (100) is configured to:record and update charge data using the data logger (120); andcommunicate periodic status updates to the MCU (150) using a Transmission Control Protocol / Intemet Protocol (TCP / IP) communication protocol (155).

11. The Rack Management System (RMS), as claimed in claim 7, wherein the RMS (100) is configured to initiate at least one quarantine measure to isolate at least one faulty battery pack, wherein the RMS (100) is configured to:disable charging and discharging of the at least one faulty battery pack by transmitting a control command to the charge controller (142) over a first Control Area Network (CAN-C) (147);flag a compartment (140) containing the at least one faulty battery pack; andprevent swapping authorization of the at least one faulty battery pack.

12. The Rack Management System (RMS), as claimed in claim 7, wherein the RMS (100) sis configured to provide bidirectional power flow to allow energy to be fed back to a grid connected to the charging and interchange station, based on state of charge of the batteiy pack, grid demand signals, and energy management policies of the charging and interchange station.

Images