Apparatus for removing and installing a battery for an electrically driven vehicle and related method
11813956 · 2023-11-14
Assignee
Inventors
Cpc classification
B60L53/80
PERFORMING OPERATIONS; TRANSPORTING
International classification
B60L53/80
PERFORMING OPERATIONS; TRANSPORTING
Abstract
It is described herein an apparatus for removing and installing a battery for an electrically driven vehicle, and a related method for removing and installing a battery into an electrically driven vehicle. The apparatus may comprise a guide system, a battery containment structure, and a linear motion device. The guide system may comprise a first track and a second track. The battery containment structure may comprise a first plurality of bearings and a second plurality of bearings, and may be configured to receive and hold the battery. When the battery containment structure is acted upon by a linear force applied by the linear motion device to lower and raise the battery containment structure, the first plurality of bearings moves linearly along the first track while the second plurality of bearings moves linearly along the second track,
Claims
1. An apparatus for removing and installing a battery for an electrically driven vehicle comprising: a guide system comprising: a first track attached to a first location on a chassis of the electrically driven vehicle, said first track having a first track length and a first track width, and a second track attached to a second location on the chassis of the electrically driven vehicle, said second track having a second track length and a second track width; a battery containment structure comprising: a first side having a first side outer surface, a first side inner surface opposite the first side outer surface, and a first lip extending from the first side inner surface along at least a portion of a first side bottom edge, a second side having a second side outer surface, a second side inner surface opposite the second side outer surface, and a second lip extending from the second side inner surface along at least a portion of a second side bottom edge, a lower cross-member extending between the first side inner surface at a first side lower corner and the second side inner surface at a second side lower corner, an upper cross-member extending between the first side inner surface along a first side top edge and the second side inner surface along a second side top edge, a plurality of first bearings connected to the first side outer surface, and a plurality of second bearings connected to the second side outer surface; and a linear motion device attached to a third location on the chassis of the electrically driven vehicle, said linear motion device having a linear motion distance; and wherein the first track length and the second track length are each oriented substantially perpendicular to a force of gravity; the battery containment structure is configured to receive and hold the battery between the first side inner surface and the second side inner surface; the plurality of first bearings are arranged in at least a first column along the first side outer surface; a first subset of the plurality of second bearings are arranged in at least a second column along the second side outer surface; a second subset of the plurality of second bearings are arranged in at least a third column along the second side outer surface; each of the first bearings has a first bearing diameter which is substantially similar to the first track width; the plurality of first bearings are disposed within the first track; the plurality of second bearings are disposed within the second track; the linear motion device is connected to the upper cross-member; and the first track length, the second track length, and the linear motion distance are substantially equal to one another.
2. The apparatus of claim 1, wherein the plurality of first bearings comprises a first top bearing and a first bottom bearing wherein the first top bearing is connected to the first side outer surface along the first side top edge, and the first bottom bearing is connected to the first side outer surface along the first side bottom edge.
3. The apparatus of claim 1, wherein the plurality of second bearings comprises two second top bearings and two second bottom bearings wherein the two second top bearings are connected to the second side outer surface along the second side top edge, and the two second bottom bearings are connected to the second side outer surface along the second side bottom edge.
4. The apparatus of claim 1, wherein the linear motion device is selected from the group consisting of a winch, a hydraulic actuator, a pneumatic actuator, an electric actuator, a gear and chain drive, a belt and pulley drive, and a screw drive.
5. The apparatus of claim 4, wherein the linear motion device is activated by a power source.
6. The apparatus of claim 5, wherein the power source is the battery.
7. The apparatus of claim 5, wherein the power source is a secondary power source.
8. The apparatus of claim 1, further comprising the battery.
9. The apparatus of claim 8, wherein the battery is contained within a housing.
10. The apparatus of claim 9, wherein the housing comprises a plurality of devices connected to a bottom surface of the housing wherein the plurality of devices is selected from the group consisting of at least one wheel, at least one caster, and combinations thereof.
11. The apparatus of claim 1, wherein the electrically driven vehicle is an all-terrain vehicle (ATV).
12. A method of installing a battery into an electrically driven vehicle using the apparatus of claim 1 comprising the steps of: a. inserting the battery into the battery containment structure, and b. applying a first linear force to the battery containment structure using the linear motion device to lift the battery containment structure into the electrically driven vehicle chassis; wherein, during the step of applying a linear force to the battery containment structure, the plurality of first bearings moves linearly along the first track, and the plurality of second bearings moves linearly along the second track.
13. The method of claim 12, further comprising the step of: c. electrically connecting the battery to the electrically driven vehicle's control system.
14. The method of claim 12, wherein prior to the step of inserting the battery into the battery containment structure, the battery containment structure contains a partially or fully discharged battery electrically connected to the electrically driven vehicle's control system, and the method further comprises the steps of: d. applying a second linear force to the battery containment structure containing the partially or fully discharged battery using the linear motion device to lower the battery containment structure from the electrically driven vehicle chassis to the ground; e. disconnecting the partially or fully discharged battery from the electrically driven vehicle's control system; and f. removing the partially or fully discharged battery from the battery containment structure; and wherein steps d, e, and f occur prior to step a.
15. An apparatus for removing and installing a battery for an electrically driven vehicle comprising: a guide system comprising: a first track attached to a first location on a chassis of the electrically driven vehicle, said first track having a first track length and a first track width, and a second track attached to a second location on the chassis of the electrically driven vehicle, said second track having a second track length and a second track width, a battery containment structure comprising: a first side having a first side outer surface, a first side inner surface opposite the first side outer surface, and a first lip extending from the first side inner surface along at least a portion of a first side bottom edge, a second side having a second side outer surface, a second side inner surface opposite the second side outer surface, and a second lip extending from the second side inner surface along at least a portion of a second side bottom edge, a lower cross-member extending between the first side inner surface at a first side lower corner and the second side inner surface at a second side lower corner, an upper cross-member extending between the first side inner surface along a first side top edge and the second side inner surface along a second side top edge, at least one first slide plate connected to the first side outer surface, and at least one second slide plate connected to the second side outer surface; and a linear motion device attached to a third location on the chassis of the electrically driven vehicle, said linear motion device having a linear motion distance; and wherein the first track length and the second track length are each oriented substantially perpendicular to a force of gravity; the battery containment structure is configured to receive and hold the battery between the first side inner surface and the second side inner surface; the at least one first slide plate is sized and shaped to fit within the first track; the at least one second slide plate is sized and shaped to fit within the second track; each of the at least one first slide plate and the at least one second slide plate independently comprises a low friction material selected from the group consisting of ultra high molecular weight polyethylene (UHMW) plastics, bronze, powdered metal, and Teflon®; the linear motion device is connected to the upper cross-member; and the first track length, the second track length, and the linear motion distance are substantially equal to one another.
16. The apparatus of claim 15, wherein the linear motion device is selected from the group consisting of a winch, a hydraulic actuator, a pneumatic actuator, an electric actuator, a gear and chain drive, a belt and pulley drive, and a screw drive.
17. The apparatus of claim 16, wherein the linear motion device is activated by a power source.
18. The apparatus of claim 17, wherein the power source is the battery.
19. The apparatus of claim 1, wherein the battery is contained within a housing.
20. The apparatus of claim 19, wherein the housing comprises a plurality of devices connected to a bottom surface of the housing wherein the plurality of devices is selected from the group consisting of at least one wheel, at least one caster, and combinations thereof.
Description
BRIEF DESCRIPTION OF FIGURES
(1)
(2)
(3)
(4)
(5)
(6)
(7)
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(10)
DETAILED DESCRIPTION
(11) Disclosed herein is an apparatus for removing and installing a battery for an electrically driven vehicle. The apparatus is described below with reference to the FIGURES. As described herein and in the claims, the following numbers refer to the following structures as noted in the FIGURES.
(12) 10 refers to an apparatus.
(13) 20 refers to a battery.
(14) 22 refers to a housing.
(15) 24 refers to a wheel or caster.
(16) 30 refers to an electrically driven vehicle.
(17) 40 refers to a chassis.
(18) 41 refers to a first location (on the chassis).
(19) 42 refers to a second location (on the chassis).
(20) 43 refers to a third location (on the chassis).
(21) 100 refers to a guide system.
(22) 110 refers to a first track.
(23) 112 refers to a first track length.
(24) 114 refers to a first track width.
(25) 120 refers to a second track.
(26) 122 refers to a second track length.
(27) 124 refers to a second track width.
(28) 200 refers to a battery containment structure.
(29) 210 refers to a first side (of the battery containment structure).
(30) 211 refers to a first side outer surface.
(31) 212 refers to a first side inner surface.
(32) 213 refers to a first side bottom edge.
(33) 214 refers to a first side top edge.
(34) 215 refers to a first side lower corner.
(35) 216 refers to a first lip.
(36) 220 refers to a second side (of the battery containment structure).
(37) 221 refers to a second side outer surface.
(38) 222 refers to a second side inner surface.
(39) 223 refers to a second side bottom edge.
(40) 224 refers to a second side top edge.
(41) 225 refers to a second side lower corner.
(42) 226 refers to a second lip.
(43) 230 refers to a lower cross-member (of the battery containment structure).
(44) 240 refers to an upper cross-member (of the battery containment structure).
(45) 250 refers to a first bearing.
(46) 252 refers to a first bearing diameter.
(47) 260 refers to a second bearing.
(48) 262 refers to a second bearing diameter.
(49) 264 refers to a gap distance.
(50) 266 refers to a bearing span.
(51) 300 refers to a linear motion device.
(52)
(53) As shown, the apparatus (10) includes a guide system (100). The guide system may comprise at least two tracks—referred to herein as a first track (110) and a second track (120). The first track may be attached to a first location (41) on the chassis (40) while the second track may be attached to a second location (42) on the chassis.
(54) The attachment between the first track (110) and the chassis (40), and the second track (120) and the chassis may take many forms. In some embodiments the attachment may comprise an integral attachment such as welding the respective track to the chassis or manufacturing the chassis and the respective track from a single integral piece of material. In other embodiments, the attachment may comprise a fastened attachment in which a third component such as one or more bolts (with or without a nut), one or more screws, one or more rivets, and combinations thereof attach the respective track to the chassis.
(55) Each of the first track length and the second track length may be oriented substantially perpendicular to or perpendicular to a force of gravity. In other words the length dimension of each track extends towards and away from the ground while the width dimension of each track extends substantially parallel to or parallel to the ground.
(56)
(57) As shown in
(58) Similarly, as also shown in
(59) As shown in
(60) In some embodiments, the bearings (first bearings and/or second bearings) may be replaced by one or more slide plates. When used, the slide plates may be sized and shaped to fit within the respective first track and/or second track. That is to say that the slide plates will have an external cross sectional profile which is similar to that of an internal cross sectional profile of the respective track, and a size which is slightly smaller than the respective track in height and width dimension(s). By slightly smaller it is meant that each dimension of the slide plate is no more than 1 cm less than the corresponding dimension of the track with no more than 0.5 cm less than the corresponding dimension of the track being more preferred, and no more than 0.1 cm less than the corresponding dimension of the track being most preferred. The slide plate(s) will preferably be made of a low friction material. Examples of such low friction materials including ultra high molecular weight polyethylene (UHMW) plastics, bronze, powdered metal, and Teflon®. The slide plate(s), when used may be connected to the battery containment structure using similar connection mechanisms to that of the bearings, including fasteners such as a bolt, a screw, a rivet, or the like.
(61) The lower cross-member (230) may extend between the first side inner surface (211) at a first side lower corner (215) and the second side inner surface (221) at a second side lower corner (225) as shown in
(62) The apparatus (10) for removing and installing the battery for an electrically driven vehicle may also comprise a linear motion device (300). The linear motion device may be selected from the group consisting of a winch, a hydraulic actuator, a pneumatic actuator, an electric actuator, a gear and chain drive, a belt and pulley drive, and a screw drive. The preferred linear motion device is a winch.
(63) The linear motion device (300) may have a linear motion distance. As used herein and in the claims—the term linear motion distance refers to the distance which the linear motion device travels between a fully extended position (i.e.—with the battery containment structure in a lowered position as shown in
(64) The linear motion device (300) may be electrically connected to, and thereby activated by a power source. In some embodiments the power source may be the battery (20). In other embodiments, the power source may be a secondary power source, such as a second battery. The second battery may be a 12 volt, 12 amp battery of the lead acid variety. However, the second battery could also be of lithium ion or other varieties. In some embodiments, the secondary power source may be electrically connected to the battery to receive an electrical charge from the battery.
(65)
(66) As shown in
(67)
(68) The number of first bearings in the plurality of first bearings (250) is not considered important, and may be selected from the group consisting of between 1 and 50, between 1 and 25, between 1 and 10, and between 1 and 5. As shown in
(69)
(70) As shown in
(71) In embodiments where the second bearings (260) are arranged in two columns along the second side outer surface (221), the plurality of second bearings can be thought of as belonging to two subsets. A first subset of the plurality of second bearings may be arranged in at least a second column along the second side outer surface, while a second subset of the plurality of second bearings may be arranged in at least a third column along the second side outer surface.
(72)
(73) In embodiments where the second bearings (260) are arranged in two columns along the second side outer surface (221), there will be a bearing span (266). The bearing span refers to the sum of two of the second bearing diameters (262) within an individual row and the gap distance (264) between the outer edge of the two second bearings in said row.
(74) In practice, the bearing span (266) is preferably substantially similar to the second track width (124). This allows the second bearings (260) to enter and move along the second track (120) while also reducing rocking of the second bearings within the second track during operation. By substantially similar it is meant that the bearing span is equal to or slightly smaller than the second track width (124). By slightly smaller than the second track width, it is meant that the bearing span is in a range selected from the group consisting of between 0.1 mm and 1 cm less than the second track width, between 0.1 mm and 5 mm less than the second track width, between 0.1 mm and 1 mm less than the second track width, between 1 mm and 1 cm less than the second track width, between 1 mm and 5 mm less than the second track width, and between 5 mm and 1 cm less than the second track width.
(75) The number of second bearings of the plurality of second bearings (260) in each column is not considered important, and may be selected from the group consisting of between 1 and 50, between 1 and 25, between 1 and 10, and between 1 and 5. As shown in
(76) While
(77) In use, the plurality of first bearings (250) will be disposed within the first track (110). This allows the first bearings to move linearly along the first track when the battery containment structure (200) is acted on by a force applied by the linear motion device (300). Similarly, the plurality of second bearings (260) will be disposed within the second track (120). This allows the second bearings to move linearly along the second track when the battery containment structure is acted on by a force applied by the linear motion device.
(78)
(79) As shown in
(80) For new battery installations, the battery containment structure may not contain a battery during this step. For battery replacements, the battery containment structure may contain a partially or fully discharged battery, which is then disconnected from the electrically driven vehicle's control system, and removed from the battery containment structure.
(81)
(82) In some embodiments, the battery (20) may be contained within a housing (22) as shown in
(83)
(84) The method as shown in
(85)
(86) The battery (20) for an electrically driven vehicle may be electrically connected to the vehicle's control unit so that an electric current from the battery is transferred to an electric motor (not shown) when the vehicle's throttle is activated. The electric motor then converts the electric current from electrical energy to rotational energy, and transfers that rotational energy to the electrically driven vehicle's drivetrain. In some embodiments, the electric current from the battery may also be used to power other electrical devices contained on the electrically driven vehicle such as lights, horns, sirens, gauges, and the like (not shown).
(87) The preferred battery is a 72 volt 100 amp lithium style battery. The lithium style battery may be a lithium ion battery, a lithium polymer battery, or a lithium prismatic battery.
(88) The apparatus and method disclosed herein allows an electric vehicle operator to quickly and easily lower the electric vehicle battery to ground level without requiring the operator to lift the heavy battery or contort their body underneath the vehicle. Once lowered to ground level, the operator can easily remove a partially or fully discharged battery, replace it with a charged battery, and position the battery back in the vehicle—again without the operator having to lift the heavy battery or contort their body underneath the vehicle. In this manner, an electric vehicle can receive a fresh, fully charged battery that is ready for operation without having to wait for a charging station to recharge the electric vehicle's battery.