Systems and Methods for a Public Standard Interface for Material Handling Vehicles

Abstract

Provided are systems and methods for a public standard interface including a Battery Management System that allows for communication between an alternative energy source and a material handling vehicle. The alternative energy source may be a Lithium Ion Battery, a fuel cell, or another non-lead acid based battery. The Battery Management System is coupled with a CAN bus that allows for communication between the material handling vehicle and the alternative energy source. The CAN bus communicates information such as a type of the energy source, energy output limits, electric current limits and information such as an energy demand profile of the vehicle. Also included is an interface between the Battery Management System and Charger Control System.

Claims

1. A system implementing a public standard interface for a material handling vehicle comprising: an energy source including a battery management system; a CAN bus coupled to the battery management system and in communication with a truck control system of the material handling vehicle; wherein the battery management system is operable to communicate: a type of the energy source, one or more limits of the energy source, and a disconnect warning.

2. The system implementing the public standard interface of claim 1, wherein a WAKE line influences the battery management system and controls a battery disconnect switch.

3. The system implementing the public standard interface of claim 1, wherein the battery management system communicates with the truck control system via the CAN bus.

4. The system implementing the public standard interface of claim 3, wherein the battery management system receives an EDP Min Voltage from the truck control system.

5. The system implementing the public standard interface of claim 1, wherein the CAN bus uses a communication protocol utilizing little endian communication.

6. The system implementing the public standard interface of claim 1, wherein the one or more limits includes a maximum discharge current and a maximum regeneration current.

7. The system implementing the public standard interface of claim 1, wherein the CAN bus comprises an H line, an L line, and separate WAKE and RETURN lines, wherein the H Line, the L line, and the WAKE and RETURN lines are included in the same connector that carries power from the energy source.

8. The system implementing the public standard interface of claim 1, wherein the energy source is a Lithium Ion Battery.

9. A system implementing a public standard interface comprising: a lithium ion battery having a battery management system in communication therewith; a CAN bus in communication with a material handling vehicle and the battery management system; wherein the battery management system is operable to communicate; a weight of the lithium ion battery, one or more limits of the energy source, and a disconnect warning.

10. The system implementing the public standard interface of claim 9 further in communication with a truck control system that communicates using the CAN bus.

11. The system implementing the public standard interface of claim 10, wherein the battery management system receives an EDP Min Voltage from the truck control system via the CAN bus.

12. The system implementing the public standard interface of claim 9, wherein the one or more limits include a maximum discharge current and a maximum regeneration current.

13. The system implementing the public standard interface of claim 9, wherein the CAN bus comprises a H line, an L line, and a WAKE and RETURN lines, wherein the H line, the L line, and the WAKE and RETURN lines are included within a single connector that carries power from the energy source to the material handling vehicle.

14. A method of communication between a material handling vehicle and a battery management system comprising: providing a communication protocol to the material handling vehicle; controlling an energy source disconnect switch; transferring energy source information between the material handling vehicle and the battery management system; and determining a type of the energy source.

15. The method of communication of claim 14, wherein the energy source information includes a weight of the energy source.

16. The method of communication of claim 14, wherein the energy source information includes an electric current output limit, a power output limit, and an energy output limit of the energy source.

17. The method of communication of claim 14, wherein the energy source information includes a current limit for the energy source.

18. The method of communication of claim 14, further comprising determining a minimum level of energy at which the energy source requires maintenance.

19. The method of communication of claim 14, further comprising determining a maximum discharge current and a maximum regeneration current.

20. A method of communication between a battery management system and a charger control system comprising: providing a communication protocol to the charger; controlling the charging process by setting current and maximum voltage levels; transferring energy source information between the battery management system and the charger for display on the charger; determining a type of the energy source; and providing for automatic shutdown of the charging electric current if the connection between the battery management system and the charger control system is broken.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] FIG. 1 is a perspective view of a material handling vehicle utilizing a standard interface according to the present disclosure.

[0019] FIG. 2 is an example signal wire pinout for an EBC type connector between an embodiment of a battery management system and a material handling vehicle.

[0020] FIG. 3 is an example signal wire pinout for an SBX type connector between another embodiment of a battery management system and a material handling vehicle.

[0021] FIG. 4 is a perspective view of an exemplary EBC type connector.

[0022] FIG. 5 is a perspective view of an exemplary SBX type connector.

[0023] FIG. 6 is a schematic of a system implementing a public standard interface including a battery management system connected to a truck control system.

[0024] FIG. 7 is an example signal wire pinout for a connector between an embodiment of a battery management system and a charger.

[0025] FIG. 8 is a schematic of information transferred between a battery management system and a truck control system.

[0026] FIG. 9 is a schematic of another mode of operation of the battery management system.

DETAILED DESCRIPTION

[0027] Before any embodiments are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.

[0028] The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the invention.

[0029] It is also to be appreciated that material handling vehicles are designed in a variety of configurations to perform a variety of tasks. Although the material handling vehicle described herein is shown in the figure as a reach truck, it will be apparent to those of skill in the art that the present invention is not limited to vehicles of this type or purpose, and can also be provided in various other types of material handling vehicle configurations, including, for example, pallet trucks, order pickers, narrow-aisle turret trucks, and any other material handling vehicle.

[0030] Turning to the figures, the following description and drawing figures pertain to embodiments of the invention directed to a system implementing a public standard interface including a Battery Management System (BMS) and an alternative energy source that provides power to a material handling vehicle. The BMS is connected to an energy source, which is preferably a Lithium Ion battery (LIB) or a fuel cell, but it will be apparent to one having ordinary skill in the art that other rechargeable batteries may be used including, but not limited to: a flow battery such as a vanadium redox battery, a zinc-bromine battery, or a zinc-cerium battery; a Lithium air battery; a Lithium-ion battery such as a beltway battery, a Lithium ion manganese oxide battery, a lithium ion polymer battery, a lithium iron phosphate battery, a lithium-sulfur battery, or a Lithium-titanate battery; a molten salt battery; a nickel-cadmium battery; a nickel hydrogen battery; a nickel-iron battery; a nickel metal hydride battery; an organic radical battery; a polymer-based battery; a polysulfide bromide battery; a potassium-ion battery; a rechargeable alkaline battery; a rechargeable fuel battery; a silicon air battery; a silver-zinc battery; a silver calcium battery; a sodium-ion battery; a sodium-sulfur battery; a sugar battery; a super iron battery; or an ULTRABATTERY®.

[0031] Most material handling vehicles currently use only Lead Acid battery (LAB) technology for traction power and lifting. By using a LIB or other new energy source, the following potential improvements result over the current use of LABs. First, a wider temperature range of operations can be achieved, for example within freezers. Second, opportunity charging can be achieved. Opportunity charging is the act of charging a battery during break time, lunch time, or any opportunity that presents itself during the work day. Third, because LIBs and Fuel Cells have a higher energy per volume, new truck designs can be achieved for historically difficult spaces, such as narrow aisles. Finally, very low maintenance is required for LIBs compared to flooded LABs. The purpose of this specification is to provide a standard for manufacturers of lithium ion batteries and material handling vehicles that defines the interface between a lithium energy source and the vehicle. Also this specification defines the interface between the lithium energy source and the charger. This standard is now public for all manufacturers, including manufacturers of vehicles, batteries, chargers, etc.

[0032] Referring to FIG. 1, a material handling vehicle 20 embodying an aspect of the invention is shown. The material handling vehicle 20 includes a body 22, a fork carriage 24 with at least one load bearing fork 26, a motor compartment (not shown) housing a motor (not shown), an energy source compartment 30 for housing an energy source 14, a battery management system (BMS) 12, and an operator compartment 34.

[0033] The terms State Of Charge (SOC) and Battery State of Charge (BSOC) are used with these definitions: BSOC is the number displayed on the truck for the operator, also called Display BSOC. BSOC ranges from 100%=100% SOC to 0%=some real SOC above 0% SOC. What 0% Display BSOC means is the operator should go charge the battery even though it may support operation for some time before the BMS must disconnect to protect the battery. Depending on the energy source chemistry, the energy source 14 may be damaged if any one cell therein is reduced to 0% State of Charge (SOC). The BMS 12 can consume power as long as it is “awake,” and holding the energy source disconnect switch closed also consumes power. Therefore, certain features in the hardware and software of the BMS 12 are provided to protect the energy source 14 during storage while inside the material handling vehicle 20, or stored outside of the material handling vehicle 20. The BMS 12 takes action when the SOC reaches a Minimum Storage Charge (MSC) level. Typically MSC is about 20% SOC or lower.

[0034] Referring to FIGS. 2 and 3, the connectors and electrical schematics for some components of embodiments of a system that implements a public standard interface 10 are shown. Note that contact 25 is an optional contact, typically a contact in the vehicle Key ON switch. Contact 25 breaks the WAKE line, thus shutting down the disconnect contactor in the battery and saving the energy required to keep a shut down truck energized. As shown in FIG. 6, the system implementing the public standard interface 10 includes the BMS 12 in communication with the energy source 14, which can be any one or more of the batteries described above to be installed in a material handling vehicle. Also in the material handling vehicle 20 is a Control Area Network (CAN) bus 16 in communication with the material handling vehicle 20. Communication of the energy source 14 with the material handling vehicle 20 and vehicle power are both carried on one standard connector, such as an EBC type connector or an SBX type connector. FIG. 2 shows a first signal wire pinout 40 for an EBC type connector 60 as shown in FIG. 4. FIG. 3 shows a second signal wire pinout 42 for an SBX type connector 62 used for signals and other purposes. The CAN bus 16 is required between the energy source 14 and the material handling vehicle 20. This is done through a single connector 60/62 for both communication and power.

[0035] Still referring to FIGS. 2 and 3, with reference to the signal wire pinouts 40, 42, a WAKE UP or WAKE line 44 tells the energy source 14 to supply power when it is shorted to a RETURN line 48. This WAKE UP function removes power from the energy source 14 when it is not plugged into an appropriate material handling vehicle or charger connector. Opening the WAKE line 44 causes the BMS 12 to open the energy source contactor and shut off power to the material handling vehicle 20 (or connection to a charger) in no more than two seconds. The BMS 12 uses the WAKE line 44 to detect when the energy source 14 is plugged into the material handling vehicle 20 and for other purposes when the energy source 14 is plugged into a charger. As further shown in FIG. 2, an H line 50 an L line 52 support the CAN bus 16, which uses the RETURN line 48 as its ground reference. As would be apparent to one of ordinary skill in the art, in material handling vehicles, both the NEGATIVE power cable 46 and the POSITIVE power cable 49 are isolated from the vehicle frame.

[0036] As shown in FIG. 6, the BMS 12 communicates via the CAN bus 16 with a truck control system (TCS) 18. In an exemplary embodiment, the BMS 12 controls a battery disconnect switch 54 as seen in FIG. 6. By controlling the battery disconnect switch 54, the BMS 12 protects the energy source 14 by shutting down the energy source 14 when certain identified conditions are satisfied, such as, but not limited to, a minimum level of available power or a minimum temperature. To power the TCS 18, the BMS 12 receives a signal via shorting the WAKE UP line 44 to the RETURN line 48, at which point the BMS 12 closes battery disconnect switch 54 to supply electric power to the TCS 18, thereby starting up the TCS 18. The BMS 12 uses the CAN bus 16 to communicate back to the TCS 18 the following information about limits of the energy source: current limit on discharge current, and current limit on the charge current (e.g., regenerative, regen or plugging current) that can be accepted.

[0037] The communication pins between the energy source 14 and the material handling vehicle 20 tolerate shorts to the ground pin and all other pins in the connector 60/62 without damage to the interface. The following list describes the function of the CAN messages defined in the Process Data Objects (PDOs).

PDO1(rx) Sent from the TCS 18 to the BMS 12 [0038] EDP Min Voltage: the minimum voltage the truck can survive without shutting down.
PDO1(tx) sent from the BMS 12 to the TCS 18 [0039] Status: register of bits [0040] bit 5 Toggle bit to confirm CAN is working [0041] bit 6 Not used [0042] bit 7 Battery Disconnect imminent [0043] Display BSOC: State of Charge displayed for the operator [0044] Fault Codes: two bytes of codes defined by the battery manufacturer [0045] Battery voltage: battery output voltage [0046] Battery current: battery current
PDO2(tx) sent from the BMS 12 to the TCS 18 [0047] Max discharge current: the maximum current that the battery can provide with battery voltage above EDP Min Voltage and will not harm the battery [0048] Max regenerative current: the maximum charging current that will not harm the battery, or exceed the truck's maximum operating voltage [0049] Temp. Highest: temperature degrees C. of hottest cell, most recent data [0050] Temp. Lowest: temperature degrees C. of coldest cell, most recent data [0051] SOH: State of Health

[0052] In an exemplary embodiment and referring to FIG. 7, the energy source 14 is charged with an external, separate charger 100 that is not mounted on the material handling vehicle 20. At least the following CAN Interface method is available for charging the energy source. The CAN Interface method of charging can be used when the energy source manufacturer supplies a CAN bus link to communicate with the charger. CiA 418 object definitions are utilized with this method of charging. The BMS 12 controls the charging process by telling the charger 100 Maximum Current AND Maximum Voltage limits throughout the charging process. Other commands to start/stop charging and convey status are implemented by the battery manufacturer to be compatible with the charger 100.

[0053] Still referring to FIG. 7, this interface includes a connector 102 having a contact 104 (i.e., the WAKE & RETURN circuit) in the connector 102 to suppress arcing if the operator disconnects the power cables during charging. A communication bus 116 to connect the energy source 14 to the charger 100 is necessary. For the CAN Interface method, the communication bus 116 is a BMS CAN bus connector, which is also used for communication with the material handling vehicle 20. Separation of the contact 104 in the connector 102 from the charger immediately stops charging to suppress arcs. Further, a lack of CAN communication for more than one second shuts down the charging process. For this method, the battery manufacturer is both responsible for the charging profile and establishing communication with the charger.

[0054] For the foregoing method of charging, the charger manufacturer provides fully automatic battery charging, including constant current, constant voltage, and finish voltage modes per battery supplier recommendations. The charger manufacturer also provides indications of correct operation. Fault or Status codes should be visible to an operator of the material handling vehicle 20.

[0055] The CAN communication protocol supported by the BMS 12 complies with selected parts of the CANopen standards CiA 301 and CiA 418. Multi-byte words are sent as “little endian” (as is mandated by CiA 301). In some embodiments, the CAN is a Standard CAN with 11-bit identifier with a Baud rate of 125 kbit/s, a Sample point of 75%, 3 Samples, and a Synchronization Jump Width of 2. The CAN identifiers are based on CANopen. Node ID BMS=0x1C. The following is for TCS to BMS communication:

TABLE-US-00001 Message Name CAN ID Description PDO1 (rx) 0x21C PDO1 sent by TCS (to BMS) PDO1 (tx) 0x19C PDO1 sent by BMS (to TCS) PDO2 (tx) 0x29C PDO2 sent by BMS (to TCS)

[0056] The following is for BMS to Charger Control System (CCS) communication:

TABLE-US-00002 Message name CAN ID Description PDO1 (rx) 0x22C PDO1 sent by CCS (to BMS) PDO1 (tx) 0x1AC PDO1 sent by BMS (to CCS)

[0057] To ensure that the charger 100 does not interfere with the existing nodes on the material handling vehicle CAN network, the CANopen id 0x2C is reserved for chargers. As an example, CAN COB-IDs 0x1AC, 0x22C, . . . are available for communication between the charger 100 and the BMS 12. The BMS 12 boots up and enters the operational state without the need for an NMT message. Further, the BMS 12 shall transmit the PDO message to report any faults. PDO messages are used during operational mode for dynamic data exchange. Up to 4 receive and/or 4 transmit PDO messages may be specified with varying transmission time intervals. Up to 8 bytes of data is contained in each PDO. The Data contained in each PDO along with its transmit time interval shall be static (fixed), and not configurable. Refer to CiA-301 standard for remaining PDO definitions. All PDO's (rx & tx) are sent 50 times a second (having a 20 msec period) or faster. The following is for BMS to TCS Communication:

TABLE-US-00003 Message Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 0x200 + EDP: Min Node ID Voltage, PDO1 (rx) 0x2005_05 0x180 + Status BSOC, Fault Codes, Battery voltage, Battery current, Node ID 0x2000_01 0x6081_00 0x2005_03 0x2005_02 0x2005_01 PDO1 (tx) 0x280 + Max discharge current, Max regenerative Temp. Temp. SOH Node ID 0x2006_01 current, 0x2007_01 Highest, Lowest, 2002_01 PDO2 (tx) 6010_01 6010_02

[0058] The following is for BMS to CCS communication:

TABLE-US-00004 Message Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 0x200 + TBD TBD TBD TBD TBD TBD TBD TBD Node ID PDO1 (rx) 0x180 + Charging BSOC, Temperature Temperature Battery voltage, Current Requested, Node ID Start-Stop 0x6081_00 highest lowest 0x2005_02 0x2005_01 PDO1 (tx) 0x2100_01 6010_01 6010_02

[0059] The following objects are necessary and/or useful in the interface between the BMS and Charger: 1) BMS request for specific charging current with maximum voltage limit, 2) BMS Start & Stop command; 3) BMS send BSOC to charger for display; 4) BMS sends Hottest Cell and Coldest Cell temperatures for display; 5) BMS sends Battery Voltage.

[0060] Service Data Objects (SDO) are used for non-cyclic read and write of data in BMS by TCS (SDO1). The BMS 12 is an SDO server. SDO segmented and expedited transfer is supported (see CiA 301). Below is an example of download and upload of an UNSIGNED 32 (expedited transfer):

[0061] SDO read:

TABLE-US-00005 ID D0 D1 D2 D3 D4 D5 D6 D7 SDO1 (rx) 0x40 Index0 Index1 Sub index — — — — SDO1 (tx) 0x42 Index0 Index1 Sub index b7 . . . b0 b15 . . . b8 b23 . . . b16 b31 . . . b24

[0062] SDO write:

TABLE-US-00006 ID D0 D1 D D3 D4 D5 D6 D7 SDO1 (rx) 0x23 Index0 Index1 Sub b7 . . . b0 b15 . . . b8 b23 . . . b16 b31 . . . b24 index SDO1 (tx) 0x60 Index0 Index1 Sub index

[0063] If an object has been accessed incorrectly by an SDO, the BMS shall respond with an SDO abort transfer. Error codes according to CiA301.

[0064] The following is an Object Dictionary and Manufacturer Fault Code Table (Note: the Index_subindex labeled with an asterisk * deviate from the CiA 418 object definitions):

TABLE-US-00007 Index_subindex (hex) Name Type Access Value Description Identification 6020_01 Battery type UNSIGNED8 ro See CiA 418 appendix A 6020_02 Ah capacity UNSIGNED16 ro Rated capacity 6030_00 Battery serial UNSIGNED32 ro 1 . . . 3 Highest sub-index supported number (CiA 418) 6030_01-3 Battery serial UNSIGNED32 ro Serial number in packed ASCII number characters 1-10 (CiA 418) 6031_00 Battery ID UNSIGNED32 ro 1 . . . 5 Highest sub-index supported (CiA 418) 6031-_01-5 Battery ID UNSIGNED32 ro Battery ID in packed ASCII characters 1-20 (CiA 418) 2201_01 HwPnBase UNSIGNED32 ro hardware part no base 2201_02 HwPnExt UNSIGNED16 ro hardware part no extension 2202_01 FwPnBase UNSIGNED32 ro firmware part no base 2202_02 FwPnExt UNSIGNED16 ro firmware part no extension 2203_01 Manufacturer STRUCT OF ro bit 0-7 Manufacturer specific version FW version UNSIGNED8 bit 8-15 numbering UNSIGNED8 bit 16-23 Major Minor Revision UNSIGNED8 6020_05 Weight UNSIGNED8 ro 0-255  Battery weight, including counter weight, 10 Kg per bit 2004_01 Current UNSIGNED16 ro 0-65535 MCNC current limit, 1 A per Limit bit 2001_01 Charging UNSIGNED8 ro Start & Stop bits: Start-Stop bit 0 Start Bit 0 = 1, Stop Bit 0 = 0 bit 1 Bit 1 TBD bit 2 Bit 2 TBD bit 3 Bit 3 TBD bit 4 Bit 4 TBD bit 5 Bit 5 TBD bit 6 Bit 6 TBD bit 7 Bit 7 TBD Instant data 2000_01 Status UNSIGNED8 ro Status bits: bit 0 Error active, i.e. any of the bits bit 1 0-4 are set in the error register bit 2 (object 1001_00). bit 3 Warning active, i.e. bit 7 is set bit 4 in the error register (object 1001_00) bit 5 Error occurred during last bit 6 charge bit 7 Warning occurred during last charge Not used (should be 0) bit 5 Toggle bit to confirm CAN is working bit 6 TBD bit 7 Battery Disconnect imminent 2002_01 SOH UNSIGNED8 ro 0-255  State Of Health (%). 2005_01 Battery INTEGER16 ro −32768-32767     Battery current, 1/16 Ampere Current per bit. Average value during latest second. Discharged current is a negative value. Regenerated current is a positive value. 2006_01 Max UNSIGNED16 ro 0-65535 Present value of maximum discharge discharge current, 1/16 Ampere current per bit. No limit is indicated by value 0xFFFF. 2007_01 Max UNSIGNED16 ro 0-65535 Present value of maximum regenerative regenerative current, 1/16 current Ampere per bit. No limit is indicated by value 0xFFFF. 6010_00 Temperature INTEGER16 ro −32768-32767     Battery temperature, ⅛° C. per high bit. (CiA 418). If more than one sensor, this parameter indicates the highest temperature. 6010_01* Temperature UNSIGNED8 ro −127-127     Highest temperature, 1° C. per highest bit 2008_01 Temperature INTEGER16 ro −32768-32767     Battery temperature, ⅛° C. per low bit. If more than one sensor, this parameter indicates the lowest temperature. 6010_02* Temperature UNSIGNED8 ro −127-127     Lowest temperature, 1° C. per bit lowest 2005_02* Voltage UNSIGNED16 ro 0-65535 Battery voltage, 1/100 Volt per bit. 6081_00* BSOC UNSIGNED8 ro 0-100  State of charge (%). (CiA 418) 2005_03 Fault Codes UNSIGNED16 ro 0-65535 See Manufacturer's fault code table 2005_05 EDP Min V UNSIGNED8 ro 0-255  Minimum Truck Voltage, 1 Volt per bit. Cumulative totals 3000_02 Discharged UNSIGNED32 ro 0- Total Ah discharged, 1 Ah per Ah total (2{circumflex over ( )}32 − 1) bit 3000_03 Regen Ah UNSIGNED32 ro 0- Total Ah regenerated, 1 Ah per total (2{circumflex over ( )}32 − 1) bit 6050_00 Charged Ah UNSIGNED32 ro 0- Total Ah charged 1 Ah per bit (2{circumflex over ( )}32 − 1) (CiA 418)

[0065] The following is a Battery Manufacturer Fault Code Table which illustrates the Standard Fault Codes for Object 2005_03. No faults is always 0 decimal. Note: maximum is 65,535 decimal. If the codes shown are inadequate for the new energy source, it is the manufacturer's responsibility to add new rows and publish the expanded table for the public.

TABLE-US-00008 Fault Code, Signal/ Decimal Functionality Undesirable Behavior 0 No Faults 1 Battery State < SOC_WARNING_CAL (example 10% of Charge SOC) 2 Pack Current Charge current limit exceeded warning (pulse or continuous table) 3 Pack Current Discharge current limit exceeded warning (pulse or continuous table) 4 Pack Current Charge current limit exceeded error (pulse or continuous table) 5 Pack Current Discharge current limit exceeded error (pulse or continuous table) 6 Voltage Sense Broken Sense Wire detected Wire 7 Diagnostic Failed Diagnostic result of Hardware Self-Test Overvoltage Protection Circuit 8 Chrgr & Key Charger Connected while Key On On Wakes 9 Key On Wake Loss Of Wake Input 10 CAN PDO RX Loss of expected CAN Rx messages 11 Contactor Contactor x - open when commanded output meas closed 12 Contactor Contactor x - closed/welded when output meas commanded open 13 Contactor Contactor x - invalid coil test coil meas 14 Pack Voltages Fuse Voltage Measurement is ~0 V 15 Pack Current Internal Measurement Loss of Current 16 Cell Voltages Internal Measurement Loss of Cell Voltage 17 Cell Internal Measurement Loss of Temperature Temperatures 18 Nonvolatile Internal Loss of EEPROM storage Memory 19 Cell Cell Temperature Out of Range Hi Temperatures (>+65deg C.*) 20 Cell Cell Temperature Out of Range Lo Temperatures (<−40deg C.*) 21 Cell Voltages Cell Voltage Out of Range Hi (>+3.7 V*) 22 Cell Voltages Cell Voltage Out of Range Lo (<1.9 V*) 23 BMS Hardware Power supply or other measurement Self-Test error 24 Pack Current Hardware Over Current Circuit Latched (discharge >2600 A) 25 Cell Voltages Hardware Cell Over Voltage Circuit Latched (>4.0 V) *signifies default cell voltage or temperature limits unless noted otherwise by the energy source manufacturer.

[0066] Another function is the “Max Current with No CAN” (MCNC) function. If the energy source 14 wakes up and has no CAN communication for six seconds, it will limit the current supplied to 50 A. This MCNC function prevents use of the energy source 14 in lift trucks that do not support the public standard interface. Attempting to drive such a material handling vehicle will pull more than 50 A, thus, the BMS 12 will open the energy source contactor for at least six seconds. Cycling the WAKE UP line 44, i.e. unplugging and plugging in again, may be required to power the material handling vehicle 20. After the BMS 12 successfully establishes CAN communication, it will ignore the loss of CAN signal. The material handling vehicle 20 provides a response to the loss of CAN after it is established in a normal wake up. For example, the TCS may shut down the lift motor or limit the speed of all motors unless CAN starts up again. Continued loss of CAN ramps down all motors to either zero or creep mode.

[0067] In an exemplary embodiment, the energy source 14 is a Lithium Ion Battery (LIB). The LIB contains the required number of cells that are assembled into modules to provide power at the nominal voltage required for a material handling vehicle 20. The cells are assembled to supply the current required and controlled by the BMS 12. The BMS 12 controls the LIB at all times, and may disconnect the LIB from the material handling vehicle 20. The BMS 12 communicates, using the CAN bus 16, with the material handling vehicle 20 to convey the current and voltage limits it can support along with other status information. The BMS 12 may use the same interface to communicate with the charger 100 to control the energy source charging process. Unless a shutdown is externally requested, the energy source 14 will only disconnect due to extremely low SOC or internal problems. The BMS 12 provides advance notice to the material handling vehicle 20 before disconnecting from the energy source 14 from the material handling vehicle 20. The TCS 18 communicates with the BMS 12 to convey the minimum voltage required to keep the material handling vehicle 20 operating.

[0068] As shown in FIG. 8, when the BMS 12 is started up by asserting the WAKE line 44, energy source information 61 is transferred between the TCS 18 and the BMS 12 via the CAN bus 16. The energy source information 61 that is transferred may include a weight 63 of the energy source, which may be a weight of the counter weight CW and everything inside of it including the energy source 14, the battery management system 12, and the battery disconnect switch 54, a serial number 64 which identifies the energy source 14, a class 66 of energy source 14, or a type 68 of the energy source 14. The transfer of this information allows the TCS 18 to utilize the energy source information 61 to ensure safe and efficient power consumption by the material handling vehicle 20.

[0069] Referring to FIG. 9, during normal operation, the BMS 12 transfers energy source information 61 to support one mode of operation. The TCS 18 also displays to a user if the energy source 14 has a problem such as a low battery state of charge or a high or a low temperature, which must be addressed.

[0070] Still referring to FIG. 9, during normal operation, normal mode 72 is a current limit mode. In this mode 72, the BMS 12 communicates a first current limit 74 and a second current limit 76. In some embodiments, the first current limit 74 is a maximum discharge current. Also in some embodiments, the second current limit 76 is a maximum regen current. Both the first current limit 74 and the second current limit 76 are based on a number of factors including a battery state of charge, an operating temperature, and other factors such as a condition of the energy source. The BMS 12 is able to identify a minimum required voltage 78 for the material handling vehicle 20 based on truck information 90 provided by the TCS 18. After receiving the truck information 90 (i.e., EDP Min Voltage), the BMS 12 can calculate the maximum discharge current which will stay above the minimum required voltage.

[0071] In an exemplary embodiment, based on the battery state of charge, temperature, and other factors, the BMS 12 calculates a maximum charging current 80 from regeneration or plugging that the energy source 14 can tolerate. Also in some embodiments, the BMS 12 estimates a current internal resistance 82, of the energy source 14. Typically this internal resistance, along with other factors monitored by the BMS, is used to calculate the maximum charging and maximum discharging current levels. How the TCS 18 handles the first current limit 72 and the second current limit 76 varies with truck design, software, and any operator inputs or the configuration of the material handling vehicle 20 or TCS 18.

[0072] Referring again to FIG. 7, the connector 102 is disconnected from the material handling vehicle 20 when the charger 100 is connected, although the energy source 14 remains inside the material handling vehicle 20. This is done using the same connector for both powering the truck and charging the energy source 14. The electrical and software interface of this specification does not support both charging the battery and powering the truck at the same time.

[0073] The following table illustrates the requirements for the energy source 14 (for example, a LIB) which must be bench tested by the supplier with appropriate lengths (approximately 1M) of wire connected. The bench test shall be done according to applicable parts of EN 12895.

TABLE-US-00009 Truck test (shown here Component test for reference) Emission EN55022 class B EN12895 30-230 MHz: 30-75 MHz: 34 dBuV/m 30 dBuV/m 75-400 MHz: 34 to 45 230-1000 MHz: dBuV/m increasing with 37 dBuV/m frequency 400-1000 MHz: 45 dBuV/m (all at 10 meters) Immunity EN61000-4-3 EN12895 27-1000 MHz: 20 V/m 27-1000 MHz: 10 V/m (an alternative test method EN61000-4-6 may be used in frequency range 27-80 MHz, test level 20 V) ESD EN61000-4-2 EN12895 8 kV contact 4 kV contact 15 kV air discharge 8 kV air discharge

[0074] The energy source 14 is installed in the material handling vehicle 20 either at the factory and shipped with the completed truck or assembled with the truck at the site. Some of the energy source components may be removed and packaged separately to avoid damage during shipment per recommendation of the energy source supplier. Both the top of the energy source system and the visible sides of any counter weight used should be marked with the following: 1) Battery Manufacturer & Model Number & Serial Number & Date of Manufacture; 2) Battery Nominal Voltage; 3) Battery Nominal Capacity in Ampere Hours; 4) Battery Weight (total weight in pounds with counter weight); 5) Battery Dimensions (total size with counter weight); 6) Safety Labeling; and 7) Storage Warning for shelf life. In some embodiments, the material handling vehicle 20 has a label applied to the control panel or battery compartment indicating that the material handling vehicle 20 has been manufactured or modified to use energy sources that meet this patent's specifications.

[0075] The foregoing description was primarily directed to embodiments of the invention. Although some attention was given to various alternatives within the scope of the invention, it is anticipated that one skilled in the art will likely realize additional alternatives that are now apparent from disclosure of embodiments of the invention. Accordingly, the scope of the invention should be determined from the following claims and not be limited by the above disclosure.