Robot Assisted Modular Battery Interchanging System

• US 20160368464A1
• Filed: 06/17/2016
• Published: 12/22/2016
• Est. Priority Date: 06/17/2015
• Status: Active Grant

• Current Assignee: Ample, Inc.
• Original Assignee: Ample, Inc.
• Inventors: Hassounah, Khaled
• Granted Patent: US 9,868,421 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B60L 53/80 Exchanging energy storage elements, e.g. removable 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
• CPC Class Codes: Y02T 90/16 Information or communication technologies improving the operation of electric vehicles

Abstract

Systems and apparatus for a robotic charging station for charging a battery of an electric vehicle. A semi-autonomous portable robot is programmed to interchange depleted rechargeable batteries disposed in an electric or hybrid vehicle. Portable battery pod dispenses batteries to semi-autonomous portable robot for swap. Semi-autonomous portable robot uses navigational sensors to transport battery to predetermined position at the battery interchange location. Battery disposition and configuration data are wirelessly communicated by battery pod to semi-autonomous portable robot. Battery pod is also in electrical communication with vehicle for timely latching and unlatching of battery modules.

Claims

1. A portable exchange robot for exchanging a battery module in a vehicle, said robot comprising:

a microprocessor;

a battery tray configured to hold a modular battery unit;

a lift in mechanical communication with said battery tray, said lift to raise and lower said battery tray;

a motor in mechanical communication with said lift and in electrical communication with said microprocessor, said motor to raise and lower said lift;

a plurality of wheels that propel said portable exchange robot;

a navigation system in electrical communication with said microprocessor and at least one of said plurality of wheels to drive the dispensary robot between a modular battery dispensary and a vehicle; and

a wireless communication system in electrical communication with said dispensary and said vehicle.

2. The portable exchange robot of claim 1, further comprising a memory in electrical communication with said processor, said memory storing instructions for:

positioning said robot under said modular battery in said vehicle;

unloading a depleted battery module from said modular battery in said vehicle; and

returning said depleted battery module to said modular battery dispensary.

3. The portable exchange robot of claim 2, wherein said instructions for unloading said depleted battery further comprise:

raising said battery tray to engage said depleted battery module;

monitoring a weight on said battery tray during said raising, said weight sensed by a weight sensor on or proximal to said battery tray;

stopping said raising when said monitored weight reaches a threshold value; and

after said stopping, sending a message to said vehicle that said battery tray has engaged said depleted battery module.

4. The portable exchange robot of claim 3, wherein said instructions for unloading said depleted battery further comprise:

receiving an unlock message from said vehicle, said unlock message indicating that said vehicle has unlocked said depleted battery from said modular battery;

measuring said weight on said battery tray after receiving said unlock message; and

lowering said battery tray if said weight on said battery tray after receiving said unlock message is greater than a second threshold value.

5. The portable exchange robot of claim 1, wherein said navigation system of said portable exchange robot includes ultrasonic radar or LiDAR.

6. The portable exchange robot of claim 5 wherein said navigation system further includes an optical system having an image sensor.

7. The portable exchange robot of claim 1, wherein said battery tray includes a raised edge that secures said modular battery unit.

8. The portable exchange robot of claim 1, wherein said lift includes an elevation trellis.

9. A battery dispensary robot comprising:

a microprocessor;

a battery dispensary to retain modular battery units, said battery dispensary defined in a body of said dispensary robot;

a plurality of wheels that propel said dispensary robot; and

a navigation system in electrical communication with said microprocessor and at least one of said plurality of wheels to drive said battery dispensary robot to a first location proximal to a vehicle.

10. The battery dispensary robot of claim 9, wherein battery dispensary includes a plurality of sensors to determine the presence or absence of said modular battery units.

11. The battery dispensary robot of claim 10, wherein said sensors are in electrical communication with said modular battery units.

12. The battery dispensary robot of claim 10, wherein said sensors measure a weight of said modular battery units.

13. The battery dispensary robot of claim 10, further comprising a wireless communication system in electrical communication with a plurality of portable exchange robots.

14. The battery dispensary robot of claim 10, further comprising a robotic arm coupled to said body.

15. The battery dispensary robot of claim 14, wherein said robot arm includes an end effector configured to grip said modular battery unit.

16. The battery dispensary robot of claim 9, further comprising a camera to detect a vehicle relative position of the vehicle and a LiDAR system to detect a relative robot position of a portable exchange robot, said vehicle relative position and said relative robot position determined relative to said battery dispensary robot.

17. The battery dispensary robot of claim 16, wherein the microprocessor calculates a navigation relative position of said battery dispensary robot with respect to said vehicle.

18. The battery dispensary robot of claim 17, wherein the battery dispensary robot sends the navigation relative position to said battery dispensary robot over a wireless communication system in electrical communication said battery dispensary robot.

19. A method of exchanging battery modules in a vehicle, the method comprising:

positioning a battery exchange robot under a depleted battery module of a modular battery in said vehicle;

with said battery exchange robot, unloading said depleted battery module from said modular battery in said vehicle;

returning said depleted battery module from said battery exchange robot to a modular battery dispensary;

with said battery exchange robot, retrieving a charged battery module from said modular battery dispensary; and

loading said charged battery module in said modular battery of said vehicle.

20. The method of claim 19, further comprising:

raising a battery tray of said battery exchange robot to engage said depleted battery module;

monitoring a weight on said battery tray during said raising, said weight sensed by a weight sensor on or proximal to said battery tray;

stopping said raising when said monitored weight reaches a threshold value; and

after said stopping, sending a message from said battery exchange robot to said vehicle that said battery tray has engaged said depleted battery module.

21. The method of claim 20, further comprising:

receiving an unlock message from said vehicle, said unlock message indicating that said vehicle has unlocked said depleted battery from said modular battery;

measuring said weight on said battery tray after receiving said unlock message; and

lowering said battery tray if said weight on said battery tray after receiving said unlock message is greater than a second threshold value.

22. The method of claim 21, further comprising generating an error message if said weight on said battery tray after receiving said unlock message is lower than said second threshold value.

23. The method of claim 19, further comprising, with said battery exchange robot, receiving a battery exchange request from said vehicle, said battery exchange request including an identifier and a location of said vehicle.

24. The method of claim 19, wherein said loading comprises:

positioning said battery exchange robot under an empty module of said modular battery in said vehicle, said battery exchange robot carrying said charged battery module on a battery tray;

raising said battery tray towards an empty receptacle of said modular battery;

monitoring a weight on said battery tray during said raising;

stopping said raising when said monitored weight reaches a threshold value, said threshold value greater than a weight of said battery module; and

sending a message to vehicle that said charged battery module is secured to empty receptacle of said modular battery.