Robot assisted modular battery interchanging system

• US 9,932,019 B2
• Filed: 08/03/2017
• Issued: 04/03/2018
• Est. Priority Date: 06/17/2015
• Status: Active Grant

• Current Assignee: Ample, Inc.
• Original Assignee: Ample, Inc.
• Inventors: Hassounah, Khaled
• Primary Examiner(s): Hageman, Mark C
• Application Number:
  US15/667,830
• Publication Number:
  US 20170355354A1
• Time in Patent Office: 243 Days
• 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 modular battery unit from a modular battery in a vehicle, said modular battery comprising one or more modular battery units, said robot comprising:

a microprocessor;

a battery tray configured to hold at least one of said modular battery units;

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;

a wireless communication system operable to be in electrical communication with said modular battery dispensary and said vehicle; and

a memory in electrical communication with said microprocessor, said memory storing instructions that cause;

(i) positioning said robot under a depleted modular battery unit in said vehicle based, at least in part, on (a) an identity of said vehicle, (b) a distribution map of the modular battery unit or units, including said depleted modular battery unit, in said vehicle relative to a vehicle reference point, and (c) an identity of said depleted modular battery unit to be exchanged;

(ii) unloading said depleted modular battery unit from said modular battery in said vehicle, said instructions for unloading said depleted modular battery unit comprising;

(A) raising said battery tray to engage said depleted modular battery unit;

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

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

(D) after said stopping, sending a message to said vehicle that said battery tray has engaged said depleted modular battery unit; and

(iii) returning said depleted modular battery unit to said modular battery dispensary.

2. The portable exchange robot of claim 1, wherein said instructions for unloading said depleted modular battery unit further comprise:

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

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

4. The portable exchange robot of claim 3 wherein said navigation system further includes an optical system having an image sensor.

5. The portable exchange robot of claim 1, wherein said battery tray includes male conical fitments that mate to corresponding female conical fitments disposed on an underside of said at least one of said modular battery units.

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

7. The portable exchange robot of claim 1, wherein said instructions for unloading said depleted modular battery unit further comprise:

raising said battery tray to engage said depleted modular battery unit;

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

measuring a weight on said battery tray after receiving said unlock message said weight measured by a weight sensor on or proximal to said battery tray; and

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

8. The portable exchange robot of claim 1, wherein said memory further stores instructions for transmitting status information to said modular battery dispensary, said status information comprising a status of said portable exchange robot.

9. The portable exchange robot of claim 1, wherein said memory further stores instructions for transmitting a location of said portable exchange robot to said modular battery dispensary.

10. The portable exchange robot of claim 1, wherein said location comprises a relative location.

11. The portable exchange robot of claim 10, wherein said relative location is relative to said vehicle.

12. The portable exchange robot of claim 10, wherein said relative location is relative to a navigational landmark or beacon.