Systems and methods for recharging vehicle-mounted energy storage devices

• US 9,827,865 B2
• Filed: 12/14/2015
• Issued: 11/28/2017
• Est. Priority Date: 12/30/2014
• Status: Active Grant

• Current Assignee: GE Global Sourcing LLC (Westinghouse Air Brake Technologies Corporation)
• Original Assignee: General Electric Company
• Inventors: Zhou, Zhi, Wiegman, Herman Lucas Norbet, Berry, Irene Michelle, Salasoo, Lembit
• Primary Examiner(s): Diao, M'Baye
• Application Number:
  US14/967,967
• Publication Number:
  US 20160185243A1
• Time in Patent Office: 715 Days
• Field of Search: 320109, 104 34, 701 22, 180 685
• CPC Class Codes: B60L 53/80 Exchanging energy storage elements, e.g. removable batteries
• CPC Class Codes: B60L 58/10 for monitoring or controlling batteries
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/249 specially adapted for aircraft or vehicles, e.g. cars or trains constructional details of batteries specially adapted for electric vehicles B60L50/64
• CPC Class Codes: H01M 50/251 specially adapted for stationary devices, e.g. power plant buffering or backup power supplies
• CPC Class Codes: H01M 50/264 for cells or batteries, e.g. straps, tie rods or peripheral frames
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/12 Electric charging stations

Abstract

A vehicle battery exchange system includes a base, a gripper, a retrieval actuator that retractably and extensibly connects the gripper to the base, and a vehicle alignment feature sensing apparatus that is operatively connected at least with the retrieval actuator and is configured to cause extension of the retrieval actuator to a battery-engaging position of the gripper in response to registration of a vehicle alignment feature to the vehicle alignment feature sensing apparatus, and to cause retraction of the retrieval actuator to a battery-removing position of the gripper in response to latching engagement of the gripper with a battery that is mounted in a vehicle at a pre-defined location relative to the vehicle alignment feature that is in registration to the alignment feature sensing apparatus.

Claims

1. A system comprising:

a base;

a gripper;

a retrieval actuator that retractably and extensibly connects the gripper to the base; and

a vehicle alignment feature sensing apparatus that is operatively connected at least with the retrieval actuator and is configured to cause extension of the retrieval actuator to a battery-engaging position of the gripper in response to registration of a vehicle alignment feature to the vehicle alignment feature sensing apparatus, and to cause retraction of the retrieval actuator to a battery-removing position of the gripper in response to latching engagement of the gripper with a battery that is mounted in a vehicle at a pre-defined location relative to the vehicle alignment feature that is in registration to the alignment feature sensing apparatus.

2. The system of claim 1, wherein the gripper comprises a platform configured for engaging a first surface of the battery that is mounted in the vehicle, and includes at least one protrusion from the platform that is configured for engaging a second surface of the battery that is mounted in the vehicle when the platform engages the first surface of the battery.

3. The system of claim 1, wherein the gripper comprises a latch unit that is operatively connected with at least one contact sensor, that is configured to latchingly engage the gripper with the battery when the at least one contact sensor confirms the battery-engaging position of the gripper, and that is configured to cause retraction of the retrieval actuator upon latched engagement of the gripper with the battery.

4. The system of claim 1, further configured to send a battery-engaging signal to a vehicle battery catch controller, when the retrieval actuator is at its battery-engaging position.

5. The system of claim 1, further configured to send a ready signal to a vehicle traction system for maintaining the vehicle at a constant velocity while the retrieval actuator extends to its battery-engaging position.

6. The system of claim 5, further configured to send a completion signal to the vehicle traction system for permitting vehicle acceleration when the retrieval actuator has been retracted to its battery-removing position.

7. The system of claim 1, further comprising a lateral actuator configured to move the gripper along a direction perpendicular to the extension and retraction of the retrieval actuator, wherein the alignment feature sensing apparatus is operatively connected to adjust the lateral actuator according to a lateral misalignment of the vehicle alignment feature from the alignment feature sensing apparatus.

8. The system of claim 1, further comprising a swivel actuator configured to rotate the gripper around an axis parallel to the extension and retraction of the retrieval actuator, wherein the alignment feature sensing apparatus is operatively connected to adjust the swivel actuator according to an angular misalignment of the vehicle alignment feature from the alignment feature sensing apparatus.

9. The system of claim 1, further comprising a housing in which the base, the gripper, and the retrieval actuator are mounted, the housing having a retrieval opening through which the retrieval actuator is configured to extend and retract the gripper, and further comprising a cover movably mounted across the retrieval opening, and a cover actuator operable to move the cover for opening or closing the housing, wherein the alignment feature sensing apparatus is operatively connected to actuate the cover actuator for opening the housing in response to registration of the vehicle alignment feature to the alignment feature sensing apparatus.

10. The system of claim 1, wherein the vehicle alignment feature is disposed on at least one surface affixed to the base, the alignment feature sensing apparatus is disposed on a vehicle movable relative to the base, and the alignment feature sensing apparatus is operatively connected with the retrieval actuator via a wireless connection.

11. A system comprising:

an energy management module;

a first rechargeable energy storage device configured for mounting to a vehicle body of a vehicle having a motor and connecting to supply power to the vehicle via the energy management module; and

a second energy storage device configured for mounting to the vehicle body and connecting to supply power to the vehicle via the energy management module;

wherein the energy management module is configured for mounting to the vehicle body and to power the vehicle including the motor from the first rechargeable energy storage device during execution of a routine operation, and from the second energy storage device in a first mode during recharging of the first rechargeable energy storage device and in a second mode during execution of a non-routine operation.

12. The system of claim 11, wherein the second energy storage device is configured to be externally mounted to the vehicle body.

13. The system of claim 12, wherein the second energy storage device includes at least one of hooks, latches, and retractable fasteners for external mounting to the vehicle body.

14. The system of claim 12, wherein the second energy storage device is configured for mounting to the vehicle body by a mounting apparatus, and to be positioned such that on detachment of the mounting apparatus, the second energy storage device will fall or slide from the vehicle body.

15. The system of claim 12, wherein the second energy storage device is configured for mounting to the vehicle body by a mounting apparatus that is disengageable from the second energy storage device by a single removing motion of the second energy storage device.

16. The system of claim 11, wherein the energy management module is configured to recharge the first energy storage device from the second energy storage device, in response to the vehicle following a route that does not include an opportunity charging station.

17. The system of claim 16, wherein the energy management module is configured to recharge the first energy storage device from the second energy storage device, only in case the vehicle cannot select a next route that does include an opportunity charging station.

18. The system of claim 11, wherein the energy management module is configured to recharge the first energy storage device from the second energy storage device, in response to receiving a signal that indicates the vehicle will divert to a route that does not include an opportunity charging station.

19. The system of claim 11, wherein the first energy storage device is an electrochemical battery, and the first energy storage device is a rechargeable power ultracapacitor with energy density in excess of 6 Wh/kg.

20. A system comprising:

a vehicle body;

a motor mounted to the vehicle body;

a first rechargeable energy storage device mounted to the vehicle body and connected to supply power to the vehicle via an energy management module; and

a second energy storage device mounted to the vehicle body and connected to supply power to the vehicle via the energy management module;

wherein the energy management module mounted to the vehicle body and connected and configured to power the vehicle including the motor from the first rechargeable energy storage device during execution of a routine operation and from the second energy storage device during a first mode of recharging of the first rechargeable energy storage device and a second mode during execution of a non-routine operation.