Battery charging and transfer system for electrically powered vehicles

• US 5,927,938 A
• Filed: 05/06/1997
• Issued: 07/27/1999
• Est. Priority Date: 01/06/1994
• Status: Expired due to Fees

• Current Assignee: Unlimited Range Electric Car Systems Company
• Original Assignee: Unlimited Range Electric Car Systems Company
• Inventors: Hammerslag, Julius G.
• Primary Examiner(s): Werner, Frank E.
• Application Number:
  US08/851,621
• Time in Patent Office: 812 Days
• Field of Search: 414/396, 414/398, 414/400, 414/401, 414/584, 414/390, 414/800, 414/806, 414/809, 104/34, 180/68.5, 320/9, 320/DIG. 34, 320/FOR 101, 194/904, 194/205
• US Class Current: 414/809
• CPC Class Codes: B60K 1/04 of the electric storage means for propulsion exchanging batteries for electric propulsion of vehicles B60L53/80; for auxiliary purposes only B60R16/04; supplying batteries to, or removing batteries from, vehicles B60S5/06
• CPC Class Codes: B60K 2001/0461 from the side
• CPC Class Codes: B60K 2001/0483 from the front
• CPC Class Codes: B60L 2200/12 Bikes
• CPC Class Codes: B60L 2260/44 by parameter estimation
• CPC Class Codes: B60L 2260/50 by future state prediction
• CPC Class Codes: B60L 3/12 Recording operating variables ; Monitoring of operating variables
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60L 53/65 involving identification of vehicles or their battery types
• 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 90/14 Plug-in electric vehicles
• CPC Class Codes: Y02T 90/16 Information or communication technologies improving the operation of electric vehicles
• CPC Class Codes: Y02T 90/167 Systems integrating technologies related to power network operation and communication or information technologies for supporting the interoperability of electric or hybrid vehicles, i.e. smartgrids as interface for battery charging of electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: Y04S 30/14 Details associated with the interoperability, e.g. vehicle recognition, authentication, identification or billing
• CPC Class Codes: Y10S 194/904 Check-operated releaser for automobile service equipment

Abstract

A battery transfer and charging system for electrically powered vehicles includes a conveyor loop for conveying batteries from a battery receiving station to a battery delivery station. A displacement assembly removes spent batteries of electric vehicles by placing charged batteries into position within the vehicles so as to laterally displace spent batteries. Spent batteries displaced from vehicles are received by the receiving station, where the batteries are tested both electrically and by comparing battery status data against predetermined criteria. Batteries which fail the battery test are automatically removed from the conveyor loop by a elevator assembly. Batteries are automatically charged as they pass through the conveyor loop in an assembly-line fashion. Following recharge, batteries are conveyed to the displacement station for installation within later vehicles. In one embodiment of the system, vehicles are processed through the system in sequential order, stopping at a specified location for battery installation/removal.

Claims

1. A method of rapidly exchanging a battery of an electrically powered two-wheel vehicle, said vehicle having a battery compartment which extends through at least a portion of the vehicle, the method comprising the steps of:

providing a battery charging and transfer station comprising;

a drive through bay including a vehicle securing station equipped with a positioning and support structure for maintaining the vehicle in an upright position; and

a continuous battery transfer conveyor within the transfer station, the conveyor having a battery receiving end which receives a partially discharged battery from a first end of the battery compartment, and having a battery delivery end which delivers a charged battery to a second end of the battery compartment, the conveyor having multiple battery positions to store and recharge multiple batteries between the receiving and delivery ends;

positioning and supporting the vehicle in an upright position within the vehicle securing station such that the battery compartment is aligned with the battery receiving and delivery ends of the conveyor, the battery compartment containing the discharged battery; and

exchanging the discharged battery with the charged battery by advancing the conveyor to shift the charged battery from the delivery end of the conveyor into the compartment and moving the discharged battery from the compartment to the receiving end of the conveyor.

2. The method of claim 1, wherein exchanging the discharged battery with the charged battery comprises advancing the conveyor by exactly one battery.

3. The method as in claim 1, wherein the step of exchanging the discharged battery with the charged battery comprises advancing at least one sprocket into an exposed area on the bottom surface of the discharged battery to shift the discharged battery from the battery compartment.

4. The method as in claim 1, wherein the step of exchanging the discharged battery with the charged battery comprises engaging at least one sprocket into an exposed area on the bottom surface of the discharged battery to lift the discharged battery from the battery compartment.

5. The method as in claim 1, further comprising advancing the vehicle through the transfer station above or below a vertically displaced segment of the conveyor without interrupting the battery transfer path between the receiving and delivery ends of the conveyor.

6. The method as in claim 1, further comprising a computer coupled to the battery transfer conveyor such that the computer programmably moves batteries by advancing the conveyor from the receiving end to the delivery end.

7. The method as in claim 1, further comprising a computer coupled to an electronic payment system, the payment system configured to allow an operator of a vehicle to specify payment source information for payment of a fee associated with a battery exchange operation.

8. A method of rapidly exchanging a battery of an electrically powered two-wheel vehicle, the vehicle having a battery compartment which extends within at least a portion of the vehicle, the method comprising the steps of:

providing a battery charging and transfer station comprising;

a drive through bay including a vehicle securing station equipped with a positioning and support structure for maintaining the vehicle in an upright position and orienting the vehicle for the battery exchange;

a continuous battery transfer conveyor within the transfer station, the conveyor having a battery receiving end which receives a discharged battery from the battery compartment, and having a battery delivery end which delivers a charged battery to the battery compartment, the conveyor having multiple battery positions to store multiple batteries between the receiving and delivery ends;

positioning and supporting the vehicle in an upright position within the vehicle securing station such that the battery compartment is aligned with the battery receiving and delivery ends of the conveyor, the battery compartment containing the discharged battery; and

exchanging the discharged battery with the charged battery by moving the charged battery from the delivery end of the conveyor into the compartment and moving the discharged battery from the compartment to the receiving end of the conveyor.

9. The method as in claim 8, wherein exchanging the discharged battery with the charged battery comprises advancing the conveyor by exactly one battery.

10. The method as in claim 8, wherein said conveyor comprises at least one battery charger for recharging batteries between the battery receiving end and the battery delivery end.

11. The method as in claim 8, wherein the step of exchanging the discharged battery with the charged battery comprises advancing at least one sprocket into an exposed area on the bottom surface of the discharged battery to shift the discharged battery from the battery compartment.

12. The method as in claim 8, wherein the step of exchanging the discharged battery with the charged battery comprises engaging at least one sprocket into an exposed area on the bottom surface of the discharged battery to lift the discharged battery from the battery compartment.

13. The method as in claim 12, wherein one or more drive sprockets engage with the discharged battery before the discharged battery is moved in the lateral direction.

14. The method as in claim 13, wherein the one or more drive sprockets move vertically and engage the discharged battery.

15. The method as in claim 8, wherein the step of exchanging the discharged battery with the charged battery comprises moving the discharged battery in a lateral direction and moving the charged battery in a lateral direction.

16. The method as in claim 15, wherein the one or more drive sprockets are arranged vertically below the discharged battery.

17. The method as in claim 8, wherein the step of exchanging the discharged battery with the charged battery comprises moving the discharged battery in a vertical direction and moving the charged battery in a vertical direction.

18. The method as in claim 8, further comprising advancing the vehicle through the transfer station above or below a vertically displaced segment of the conveyor without interrupting the battery transfer path between the receiving and delivery ends of the conveyor.

19. The method as in claim 8, further comprising a computer coupled to the battery transfer conveyor such that the computer programmably moves batteries by advancing the conveyor from the receiving end to the delivery end.

20. The method as in claim 8, further comprising a computer coupled to an electronic payment system, the payment system configured to allow an operator of a vehicle to specify payment source information for payment of a fee associated with a battery exchange operation.

21. The method as in claim 8, wherein the rapid battery exchange occurs in a period of time that is less than five minutes.