WO2010105083A1

WO2010105083A1 - Smart battery exchange system for electric/hybrid vehicles

Info

Publication number: WO2010105083A1
Application number: PCT/US2010/027023
Authority: WO
Inventors: Roger L. Haskell
Original assignee: Median Wind, Llc
Priority date: 2009-03-11
Filing date: 2010-03-11
Publication date: 2010-09-16

Abstract

In one embodiment, a battery exchange system includes a plurality of battery exchange stations, each of the plurality including a robotic arm, for engaging an removing batteries; a plurality of exchange batteries for insertion into the battery tray of the car; a plurality of cars, each car of the plurality having a battery tray holding a plurality of batteries, wherein the plurality of batteries is exchanged for a at least a portion of the plurality of exchange batteries at one of the plurality of battery exchange stations.

Description

TITLE Smart Battery Exchange System for Electric/Hybrid Vehicles

SUMMARY In one embodiment, a battery exchange system includes a car having a battery tray and a first battery on the battery tray; and a battery exchange station, including a robotic arm, for engaging an removing batteries; a plurality of a batteries for insertion into the battery tray of the car. In one alternative the battery exchange system further includes an alignment system for aligning the robotic arm with the first battery. In one alternative, the alignment system utilizes a laser. In one alternative, the laser is mounted on the robotic arm. In another alternative, the alignment system includes a sensor for receiving reflected light from the laser. Optionally, the first battery has an alignment guide. In one alternative, the alignment guide is a colored area on the battery, the colored area having a uniform variation from dark to light, wherein the lightest portion of the colored area is oriented at an alignment point for the robotic arm. Optionally, the robotic arm is aligned with the alignment point by shining the laser on the colored area, determining whether the laser is shining on the lightest portion of the colored area using the sensor, and realigning the robotic arm until it is aligned. In another embodiment, a battery exchange system includes a plurality of battery exchange stations, each of the plurality including a robotic arm, for engaging an removing batteries; a plurality of exchange batteries for insertion into the battery tray of the car; a plurality of cars, each car of the plurality having a battery tray holding a plurality of batteries, wherein the plurality of batteries is exchanged for a at least a portion of the plurality of exchange batteries at one of the plurality of battery exchange stations.

In one embodiment, a method of powering electric vehicles includes providing a plurality of exchange stations, each charging station of the plurality of charging stations including a plurality of exchange batteries; providing a plurality of vehicles containing a plurality of first batteries; exchanging from a first vehicle of the plurality of vehicles at a first exchange station of the plurality of exchange stations, a first used battery of the plurality of first batteries for a second battery of the plurality of exchange batteries; detecting the level of charge remaining in the first used battery; offsetting a monetary value to a purchasers of the second battery based on the charge remaining in the first used battery. In one alternative, the monetary value is directly proportional to a cost of energy plus a profit percentage for the operators of the plurality of battery exchange systems. In another alternative, the purchaser does not pay for the cost of the second battery. Optionally, the purchaser does not pay for the total cost of the second battery. In another alternative, the purchaser pays for the cost of the energy to charge the second battery, a service percentage, and a profit percentage but not a cost of the second battery. Optionally, the purchaser pays for a maintenance cost for the second battery.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows one embodiment of a battery exchange system;

FIG. 2 shows another embodiment of a battery exchange system;

FIG. 3 shows one embodiment of a battery exchange tray;

FIG. 4 shows one embodiment of a guide; FIG. 5 shows one embodiment of patterning on a guide; and

FIGs. 6a-6c show various positions of one embodiment of robotic arms for use with the battery exchange system.

DETAILED DESCRIPTION Vehicle batteries are exchanged individually or en mass. The system is akin to a gas station in that vehicles enter needing fuel (in this case electricity) and they leave refueled (with depleted batteries exchanged for charged batteries). The system includes the following: A battery locator (a laser is preferred) pinpoints the location of the batteries within the vehicles using a reference point system. An in-vehicle contact point releases capture points which secure the batteries (either individually or collectively in a tray). A robot (robotic arm) removes the depleted in-vehicle batteries, immediately replacing them with other charged batteries (either individually or in a tray). The charged batteries are immediately secured. The traditional positive and negative battery contact points are reconfigured to be captured as the batteries are placed in the vehicle and secured based upon their seated location. A series of these smart electric service stations form a network whereby drivers can extend the range of their vehicles without being delayed by the time necessary to recharge batteries in the vehicles. The electric/hybrid vehicle is configured so as to afford easy access for the robotic arm. Where the batteries are covered (hood) while the vehicles are being driven, that hood can be opened and closed either manually or, preferably, by the robotic arm. The exchange of batteries takes place in less time than is traditionally taken to fill a tank of gas. Vehicles share the same battery tray and battery configuration allowing for a "plug and play" interchange of batteries. Batteries are shared among vehicle owners. Smart battery stations can be supplemented as vehicle owners choose by smaller dedicated at-home robots which exchange a spare home battery or tray of batteries. The exchanged depleted batteries are then charged at home for re-use.

At the Smart Battery Exchange Stations depleted batteries are re-charged on site, or transported to larger charging centers if more convenient. The number of batteries available at any given time at any particular station is displaced on a board similar to the current price boards displayed by gas stations.

In one embodiment the system is essentially a battery tray system that, with hood tilted forward (for side load) or off side (for front load) is slid out from either front of what is traditionally engine compartment, or from the front, and picked out of place by robotic arm. A quick release tray system, akin to a file drawer, with batteries in place, can be removed and quickly replaced. The power connection is through a plug harness that is plugged in and out by hand (alternatively with better fitment the batteries plug themselves in with the assistance of the robotic arm when the tray was replaced with contacts built into the tray and the receiver). In one alternative, a tray release lever in the driver compartment is pulled to allow the tray to slide and be removed.

In one alternative, the tray dimensions are just larger than and contained two, four, and then six, standard sized batteries - with batteries in the tray. Weight dictated that for the trays to be moved quickly in a real world setting the trays would need to be picked up and moved with robots. Alternatively, the trays are moved empty, then with batteries moved with engine hoist or chain fall.

Batteries in the overall system are exchanged at stations (like gas stations) where a customer pulls in, exchanges the discharged batteries for charged batteries, and drives away, in less time than it would take to fill up a tank of gas. The exchange is accomplished by robotic arms that would access batteries either by moving the hood (side hinged, front or rear hinged), then reaching in, or by a front or side tray access hatch(s) that allowed the battery tray(s) to slide out for access. The stations charge batteries on site, and central distribution and/or charging facilities could provide charged batteries to, and pick up discharged batteries from, stations with high exchange volumes that exceed that stations onsite charging capacity.

FIG. 1 shows a method of exchanging the batteries of a vehicle at an exchange station. In step 1 10 the user pulls the vehicle into the exchange station. Visual guides assist the user in aligning the vehicle in the station, so that the vehicle position is proximate to the robotic arm and exchange batteries. In step 120 the battery drawer of the vehicle is opened. In some alternatives this drawer is oriented at a standard height in order to simply the operations of the robotic arm. Less orientation of the arm is needed in the horizontal direction in this configuration. In step 130 the robotic arm removes the plurality of batteries in the tray. In step 140 replacement batteries are inserted. In step 150, the battery drawer is closed.

FIG. 2 shows a method of exchanging batteries in a vehicle at an exchange station. In step 210 the user pulls the vehicle into the exchange station. Visual guides assist the user in aligning the vehicle in the station, so that the vehicle position is proximate to the robotic arm and exchange batteries. In step 215 the battery drawer of the vehicle is opened. In this alternative the drawer is oriented at a standard height in order to simply the operations of the robotic arm. Less orientation of the arm is needed in the horizontal direction in this configuration. The user checks the alignment of the vehicle to ensure that the robotic arm is approximately aligned with the battery tray in the vehicle. In an alternative, mirrors are oriented at the station to assist the user with this alignment. In step 220 the robot arm is initiated. The batteries in the battery drawer each have an alignment guide painted onto them to allow for the alignment of the robotic arm. The alignment guide is an area of varying color intensity. That the alignment point for the robotic arm, the color intensity is at its lowest (white). On the outer limits of the guide, the shade is darkest (in one alternative black). Between the alignment point and the other limit of the guide, the intensity fades from most intense at the outer limit, to least intense at the alignment point in a uniform fashion. The robotic arm includes a laser or other illumination device and a sensor for detecting reflection from the guide. The robotic arm initially senses the intensity of the color detected by the sensor. Then the arm moves in a left or right direction to a new point. The intensity is again detected. If the intensity has decreased, then the arm is moving in the right direction and continues moving in that direction and sensing, until the area of lowest intensity is reached. In one alternative, this process is preformed in the vertical and horizontal direction. In an alternative, if alignment in both directions is needed by the setup of the vehicles and charging station, then a multiple color guide may be used. The multiple color guide has two colors integrated with each other. The sensor is oriented to independently capture and measure the two different colors and aligned as described above.

Continuing, with FIG. 2, in step 225 and 230 the alignment is initiated and the horizontal alignment begins. The system first senses the initial color intensity and then the arm is moved in one direction. The movements of the arm are very small and appear to be continuous to the user due to the speed of processing of the software modules. In step 235 the sensor and processing system determine whether the lightest or least intense color is sensed. If no, then arm must align and in step 240 it is determined whether a lighter color is sensed. If no, then the arm is moved in the opposite direction is step 245. If yes, then the arm is moved further in the same direction in step 250. Control continues back to step 235 and it is again determined whether alignment is reached. This process continues until alignment is reached. When it is sensed that alignment is reached, in step 255, it determined that the arm is aligned. The arm then extends and performs the process of switching the batteries in step 260. Various software modules are designed to carry out the steps of FIG. 2. When the proper alignment position is detected, the system records this position for purposes of the battery exchange occurring. By recording this position the robotic arm can quickly align for purposes of positioning and inserting batteries. Other positions recorded are the position of charged batteries for retrieval. In some embodiments more than one robotic arm is used. In other embodiments the robotic arms come from above the vehicle, and battery storage is above the vehicle, for ease of movement. In one alternative, a car exchanging batteries is moved into place by a motorized conveyer, similar to that of a car wash. This procedure minimizes the miss alignment of the vehicle and battery tray in relation to the robotic arms, therefore requiring less alignment of the arms. The term robotic arms are used in a most general sense. In one alternative, the arms lower from above the vehicle and lift the battery out. FIGs. 6a-6c show a series of views of one embodiment of the robotic arms and their various alignment positions. In FIG. 6a the arms 620 are above and wide of battery 610 and contact points 630. In FIG. 6b the arms 620 are shown descending into vertical alignment with contact points 630. In FIG. 6c the arms 620 are moved into position to interface with contact points 630. Thereafter the arms lift the battery away vertically through a portal above the vehicle. The battery is then moved horizontally in the storage space above the vehicle away from the hole and stored. The arms 620 then acquire another battery in the space above the vehicle and lower the battery into place.

FIG. 3 shows one embodiment of a battery tray. A car 310 or other vehicle is designed to accommodate one or more removable batteries 320. The battery or batteries 320 are positioned on a tray 330 that slides in and out of the car 310. The tray may be positioned for front, rear, or side battery exchange. Alignment point and contact point 340 is an area on the battery 320 designed to receive the robotic arm. The contact point 340 is simply be a slot or in alternatives is a slot with special attachment and interface features. There is a corresponding contact point on the opposite side of the battery that is not shown. A firewall separates the driver compartment from the battery area in car 310. FIG. 4 shows one example of a guide for the laser and sensor. Guide 410 is painted around contact point 420 where the robot arm interfaces with the battery. The area 430 around contact point 420 has varied shading, which is darkest at the edge and lightest towards the contact point 420. The arrows 440 show the variation direction of the shading, the lead of the arrows 440 being the darkest areas and the tips of the arrows 440 being the lightest. This guide may be used in conjunction with the method described in FIG. 2, although an additional step is needed to complete the alignment algorithm. The system must start alignment in one direction, such as the horizontal, and determine that when the shading is not changing that it must then function in the vertical direction. Various other reference point systems may be used.

FIG. 5 shows one embodiment of a two color guide. In the two color guide, two different colors block are used, block color 520 and block color 530. Block color 520 varies from darkest at the lead of arrow 540 to lighter at the tip, since the contact point (not shown) is up. Block color 530 varies from darkest at the lead of arrow 540 to lighter at the tip, since the contact point (not shown) is to the right. These color blocks are printed on the guide at a very small size and oriented from light to dark shading, the darkest being furthest from the contact point for the robotic arm. Color blocks 520 only vary in shading in the vertical direction, while color blocks 530 only vary in shading in the horizontal direction, similar to the shading diagram shown in FIG. 4. In this way, light of the color of color blocks 520 detected by the sensor is used for vertical orientation while the color blocks 530 is used for horizontal orientation. In one alternative, sensors are oriented to detect only a limited range of wavelengths. Optionally, infrared or other non-visible wavelengths are used and projected from the laser.

Although the smart battery exchange system has been described with reference to specific embodiments, this description is not meant to be construed in a limited sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the present smart battery exchange system will become apparent to persons skilled in the art upon the reference to the disclosure.

Claims

CLAIMS I claim:

1. Battery exchange system, comprising:

(a) a car having a battery tray and a first battery on the battery tray; and

(b) a battery exchange station, including a robotic arm, for engaging an removing batteries; a plurality of a batteries for insertion into the battery tray of the car.

2. The system of claim 1 , wherein the battery exchange system further includes an alignment system for aligning the robotic arm with the first battery.

3. The system of claim 2 wherein the alignment system utilizes a laser.

4. The system of claim 3, wherein the laser is mounted on the robotic arm.

5. The system of claim 4, wherein the alignment system includes a sensor for receiving reflected light from the laser.

6. The system of claim 5, wherein the first battery has an alignment guide.

7. The system of claim 6, wherein the alignment guide is a colored area on the battery, the colored area having a uniform variation from dark to light, wherein the lightest portion of the colored area is oriented at an alignment point for the robotic arm.

8. The system of claim 8, wherein the robotic arm is aligned with the alignment point by shining the laser on the colored area, determining whether the laser is shining on the lightest portion of the colored area using the sensor, and realigning the robotic arm until it is aligned.

9. A battery exchange system comprising:

(a) a plurality of battery exchange stations, each of the plurality including: a robotic arm, for engaging an removing batteries; a plurality of exchange batteries for insertion into the battery tray of the car;

(b) a plurality of cars, each car of the plurality having a battery tray holding a plurality of batteries, wherein the plurality of batteries is exchanged for a at least a portion of the plurality of exchange batteries at one of the plurality of battery exchange stations.

10. A method of powering electric vehicles, the method comprising:

(a) providing a plurality of exchange stations, each charging station of the plurality of charging stations including a plurality of exchange batteries;

(b) providing a plurality of vehicles containing a plurality of first batteries;

(c) exchanging from a first vehicle of the plurality of vehicles at a first exchange station of the plurality of exchange stations, a first used battery of the plurality of first batteries for a second battery of the plurality of exchange batteries;

(d) detecting the level of charge remaining in the first used battery;

(e) offsetting a monetary value to a purchasers of the second battery based on the charge remaining in the first used battery.

1 1. The method of claim 10, wherein the monetary value is directly proportional to a cost of energy plus a profit percentage for the operators of the plurality of battery exchange systems.

12. The method of claim 10, wherein the purchaser does not pay for the cost of the second battery.

13. The method of claim 10, wherein the purchaser does not pay for the total cost of the second battery.

14. The method of claim 10, wherein the purchaser pays for the cost of the energy to charge the second battery, a service percentage, and a profit percentage but not a cost of the second battery.

5. The method of claim 10, wherein the purchaser pays for a maintenance cost r the second battery.