GB2027653A

GB2027653A - Method of handling a battery pack for a battery powered vehicle

Info

Publication number: GB2027653A
Application number: GB7926667A
Authority: GB
Original assignee: Lucas Industries Ltd
Current assignee: ZF International UK Ltd
Priority date: 1978-08-03
Filing date: 1979-07-31
Publication date: 1980-02-27
Also published as: GB2027653B

Abstract

A method and apparatus for handling a battery pack (11) for a battery powered vehicle comprising mounting the battery pack (11) on a platform (16) having an air chamber (25) beneath it and air bags (27, 28) thereon, admitting air to the chamber to allow movement of the apparatus and raising the battery pack to fit into a location beneath the vehicle by inflating the bags (27, 28) the support of the platform (16) on the air cushion beneath it being removed by cutting of the supply of such air to allow the platform (16) to sink onto the floor, the removal of a battery pack involving the opposite procedure of swinging the platform (16) to a position beneath the battery pack, inflating the bags (27, 28) to support the weight of the battery pack (11), allowing platform to sink to the ground and then deflating the bags to lower the battery pack (11), before withdrawing the whole assembly from beneath the vehicle. <IMAGE>

Description

SPECIFICATION Method of handling a battery pack for a battery powered vehicle The invention relates to a method of handling a battery pack while fitting it to or removing it from a battery powered vehicle.

A battery pack for such a vehicle comprises a number, sometimes a large number, of individual batteries mounted in a frame. The complete assembly of batteries and frame may be removed for inspection or maintenance, or a different newly charged pack may be fitted, the vehicle being rendered immobile, without power, for this time, which however should be as short as possible.

Conventional arrangements for removing and fitting the battery pack involve the use of a wheeled trolley on which the battery pack rests.

This has a lifting jack system so that, when the battery pack is to be fitted, it can be wheeled under the vehicle in a lowered position, and when in the correct location, it is lifted into position at which fasteners are secured to hoid it in place. The reverse procedure is followed when the battery pack is to be removed.

With such a wheeled trolley and lifting jack system, it is difficult to fit the battery pack because it is difficult to align the pack accurately before lifting by means of the jack system and when lifted, it is difficult to wheel it into the correct position without fouling adjacent parts of the vehicle. The wheeled trolley, whilst it may be capable of movement in any direction, by means of castor wheels, is not easily manoeuvred, this being due to inaccessibility under the vehicle and to the great weight of the battery pack and trolley rendering castor action somewhat inefficient.

There have however been proposed, for uses other than for battery pack handling, that is for general load handling, devices which in use move upon a cushion of air, that is on the hovercraft principle. These have the advantage that they are easily moved in any direction, so that alignment where required is much more readily accomplished.

It is the object of the invention to provide a method of handling a battery pack for a battery powered vehicle in a convenient and simple manner which permits easy alignment of the battery pack as well as convenient raising and lowering during fitting and removal of the battery pack, whereby rapid changing of a battery pack in a vehicle can be accomplished so that the vehicle is rendered immobile for the shortest time.

According to the invention there is provided a method of handling a battery pack for a battery powered vehicle comprising, for fitting the pack to a vehicle, mounting the battery pack on a support device which has means for raising upon a cushion of air, manoeuvring the pack under the vehicle to a position substantially aligned with and below a required position, inflating one or more bags on the support device to raise the battery pack thereon into a position in which it can be secured to the vehicle, the raising of the battery pack into contact with the vehicle, causing the support device to sink into contact with a supporting surface, and for removal of the battery pack being accomplished by releasing the pack from the vehicle while the weight thereof is supported by the support device with the inflatable bag or bags inflated, then deflating the bag or bags, allowing the support device to rise on its cushion of air, arid then manoeuvring the support device with the battery pack from beneath the vehicle.

According to a further aspect the invention resides in apparatus for handling a battery pack for a battery powered vehicle, comprising a support device having means for raising the support device upon a cushion of air and at least one inflatable bag on the support device and on which a battery pack can be supported on the apparatus, the area of the support device subject to the air cushion and that in contact with the bag or bags, when inflated, being so chosen that, when the battery pack is raised into contact, in use, with a vehicle to which it is to be fitted, the support device will sink into contact with a supporting surface.

The invention will now be described by way of example, with reference to the accompanying drawings, in which: Figure 1 (a) to (d) are diagrammatic views of an electric drive vehicle with a battery pack handling device during the removal of the battery pack during successive stages, in accordance with the invention; Figure 2 (a) to (e) are diagrammatic views of the vehicle and the device during successive stages in the fitting of the battery pack, Figure 3 is a perspective view of a support device constructed in accordance with the invention and shown carrying a battery pack, Figure 4 is a diagrammatic representation of the support device showing the air supply arrangements, Figure 5 is a similar view to Figure 4 showing an alternative construction, Figure 6 is a similar view of a still further alternative construction, Figure 7 is a perspective view of part of the platform of the support device, Figure 8 is a side elevation view of a quick release coupling for the air supply, and Figure 9 is a fragmentary perspective view showing the handle and part of the platform of the support device.

Figures 1 and 2 show a vehicle indicated generally at 10, which in this example, is a medium or light weight goods carrying vehicle.

This is of the kind powered by electrical storage batteries which supply electric power to an electric motor driving the rear wheels of the vehicle.

Figure 3 shows the battery pack 11 which comprises a plurality of individual storage batteries 12 which are of the multi-cell type and which are electrically interconnected in known manner, these being mounted in a frame 14. The batteries are electrically connected to a common electrical socket arrangement (not illustrated) which can be releasably connected with wiring fitted into the vehicle.

The battery pack is mounted beneath the vehicle and is secured in place by a number of fastening elements. In one example each fastening elements is in the form of an upright lug 13 which is secured on the frame 14. This engages in an appropriate socket in the vehicle chassis and a pin 15 is engaged in the lug and in a hole within the socket aligned with It in the chassis socket.

Provision is made to guide the battery pack into a position of proper alignment of the lugs with the sockets during the fitting procedure of the battery pack into the vehicle.

In an alternative arrangement however, the battery pack is secured into place by spring loaded hooks carried on the vehicle chassis. These are preferably automatically engageable as the battery pack reaches the correct location but must be manually released. Provision may be made for manual release ata remote position. In this example furthemore, a ball and socket locating device may be provided at one end of the battery pack, the spring loaded hooks being provided at two sides respectively, so that the battery pack is mounted at three points.

In Figure 3 the battery pack is shown carried on the support device. The support device enables the battery pack to be accurately manoeuvred beneath the vehicle in any direction horizontally and to allow it to be elevated and lowered during fitting and removal procedure.

The battery pack support device comprises a readily portable platform 1 6 made of wood, metal, plastics material or any other suitable material.

Along one side of this are spaced hand hold openings 1 7 shown in Figure 7. The use of these tends to avoid an operators hand from being crushed beneath the assembly when it is lowered to the ground. On this side of the platform valve actuators 18, 1 9 and 20 are positioned in respective sockets. An operating lever 21 which is detachable can be used in conjunction with the valve actuators 1 8, 19 and 20 respectively.

On one end of the platform and shown in Figure 9 there is a handle 22 to which is attached a pair of arms 23, 24 serving as locators for guiding the battery pack into the correct position.

As shown in Figures 3, 4, 5 and 6 the platform has a space or chamber beneath it indicated at 25 into which air can be supplied. Surrounding this space is a hollow skirt 26. The skirt is made from a flexible material and also has provision for entry of air into its interior. Mounted on top of the platform are a number of individual air bags 27, 28. These directly support the battery pack 11 as shown in Figure 3.

Air supply to the platform and thence to the chamber 25, the skirt 26 and the bags 27, 28 is obtained from a portable air compressor 29. The compressor 29 obtains air through an inlet filter 30.

In the preferred arrangement shown in Figure 4 the air is supplied from the compressor 29 into the interior of the platform 1 6 through a single flexible connection 31. This connection however includes a quickly releasable connector shown in Figure 8.

This comprises a rigid right angle bend pipe member 32 connected to the compressor 29 or to a pipe leading therefrom. To this is secured a Ushaped bracket 33 on the free ends of which is pivoted a stirrup 34 forming part of an over-centre mechanism including a pivoted pin 35 surrounded by a coiled compression spring 36 mounted on a structure fixed relatively to the bracket 33. The stirrup 34 is connected at 37 to a collar 38 on the end of the flexible connection 31. Figure 7 shows the connection in the coupled positon but if the over-centre mechanism is tripped, by swinging the stirrup 34, the coupling is immediately released, thus allowing air to escape. This is designed principally to be operated by the foot in case of emergency so that excess air from the. system can be spilled quickly. This is useful if the heavy battery pack were to move towards a position to crush the operator against a wall. He could kick the coupling open and release of the air to stop the assembly would be very quick, for example taking about one second.

As shown in Figure 4, within the platform 16, the connection 31 leads through a main passage 39 directly to the interior of the skirt 26. Branch passages containing respective valves 40, 41,42 lead respectively to the interior of the chamber 25 and to the interiors of the two bags 27, 28 respectively. The valve 40 can simply be opened or closed to admit or prevent entry of air to the chamber 25. The valves 41 and 42 are both three way valves and can therefore allow entry of air into the associated bag or close off such entry or alternatively allow escape of air from the bag through an exhaust outlet in the valve.

Figures 1 (a) to (d) show the sequence of operations in removing a battery pack from a vehicle. Figure 1 (a) shows the vehicle and indicates the position of the battery pack within the vehicle but accessible underneath it. Figure 1 (b) shows the platform moved beneath' the vehicle and aligned with the battery pack. To achieve this, air is admitted into the platform chamber 25, as well as into the skirt 26. This raises the platform off the ground. The height of hover is determined by the pressure in the chamber 25, as determined by valve 40, in comparison with the pressure within the skirt. Figure 1 (c) shows condiiions when the platform is correctly located beneath the battery pack. The bags 27, 28 are inflated to raise the upper surface of the bags irito contact wiTh the underneath of the battery pack. As further inflation takes place, the valve 40 is closed, thus cutting off the supply to the chamber 25. In these conditions the platform sinks on the skirt which thus rests on the ground and prevents the platform moving laterally.

When sufficient air pressure is in the bags 27, 28 to take the weight of the battery pack, the pins 1 5 are removed or in the case of the hooks these are released to allow the battery pack to be cleared from the underneath of the vehicle. Following the stage shown in Figure 1(c), the bags 27, 28 are deflated, this being achieved by opening the valves 41, 42 to exhaust. The weight of the battery pack deflates the bags.

After closing the valves 41,42, the valve 40 is reopened to allow air to enter the chamber 25 so that the whole platform, including the battery pack, can be raised sufficiently to clear the skirt 26 from the floor so that the whole apparatus can be removed from beneath the vehicle as indicated in Figure 1 (d). Preferably, the back of the vehicle is jacked up by means of portable jacks 51 to allow clearance for the battery pack.

Figure 2 shows the replacement of the same battery pack after maintenance, or fitting of a replacement battery pack. Figure 2(a) shows the vehicle rear end mounted on the jacks 51. The battery pack mounted on the platform is placed under the vehicle in a position in which the lugs or hooks will align with their associated formations.

The vehicle is now lowered to the position shown in Figure 2(c). Figure 2(d) shows the raising of the battery pack 11 on the bags 27, 28, this being accomplished with the platform lowered to the ground by allowing escape of air from the platform chamber 25.

The platform itself can be raised by increasing the pressure in the skirt as required.

Figure 2(e) shows removal of the platform after fitting of the battery pack under the vehicle.

The respective areas of the bags and of the chamber 25 beneath the platform are so chosen that when pressure is applied to take the weight of the battery pack, by inflation of the bags 27, 28, the platform will sink onto the floor instead of tending to raise the vehicle. The importance of this is to enable the platform to rest on its skirt on the floor when the weight of the battery pack is accepted, thus preventing the platform from moving laterally until required to do so.

Upon completion of the fitting of a battery pack into a vehicle it is necessary, to ensure that the bags are properly deflated before attempt is made to remove the platform from beneath the vehicle.

To deflate the bags, these are squashed against the underside of the battery pack by increasing the skirt height. The valves 41,42 are opened to exhaust so that the air in the bags is expelled.

In the alternative construction shown in Figure 5, two supply pipes lead from the compressor 29 to the platform 1 6. These are identified at 43, 44 respectively. These communicate with respective internal passages 45, 46 within the platform 16.

The passage 45 leads directly to the skirt 26 and a branch passage including a valve 47 leads to the chamber 25. The other passage 46 leads through the two valves 48,49 to the two bags 27,28 respectively. A change-over valve 50 is associated' with the compressor 29 to allow appropriate supply. The valve 50 is in a linking pipe 50a between the inlet and the outlet of the compressor. The inlet from the filter 30 includes a further valve 30a. The connections to the bags are at the centres of their underneath surfaces and in this way the folds of the bag, in uninflated condition, do not obstruct entry of air for inflation of the bags, nor do such folds obstruct rapid exhaust of the air when required. Plug-in connections are preferably used into appropriate sockets in the platform 16. These serve both to provide the air connection as well as the mechanical connection between the bags and the platform.

In this construction the procedure for fitting and removal of a battery pack are substantially similar to the Figure 4 arrangement already described.

However deflation of the bags is carried out by actuating the valves 50 and 30a so that air from the bags is drawn through the by pass in which the valve 50 is situated and delivered to the chamber 25, the compressor causing a suction to produce this effect.

Figure 6 shows an alternative arrangement wherein the platform 1 6 and the skirt 26 are separtately supplied through passages 52, 53 under the control of a valve 54. The valve is capable of providing supply to the two passages 52, 53 either separately or simultaneously.

The compressor supplies air to the connection 55 terminating at the valve 54 and through a quickly releasable coupling of the kind already described in relation to Figures 4 and 7. A bypass 56 between the inlet and the outlet of the compressor 29 includes a valve 57 which provides the supply connection to a passage 58 leading through passages 59, 60 to the bags 27 and 28, through valves 61 62. These valves have exhaust ports. Similarly to Figure 5 there is a valve 63 between the filter 30 and the compressor 29.

Furthermore, the bypass passage 56 terminates within the supply passage to the connection 55 in an inlet orifice indicated at 64.

The operation of this apparatus is similar to that in Figure 5. However the differential pressure for controlling the hover height is provided by the orifice 64. Positive'deflation of the bags is achieved by reversing the connections of the compressor so that it operates to provide suction instead of compression.

The procedure described can be carried out quickly and thus minimises the time during which the vehicle is immobilised. The provision of more than one bag has the advantage that adustment can be achieved between two bags to alter the alignment of the battery pack. However a single bag may be used.

Claims

1. A method of handling a battery pack for a battery powered vehicle comprising, for fitting the pack to a vehicle, mounting the battery pack on a support device which has means for raising uppn a cushion of air, manoeuvring the pack under the vehicle to a position substantially aligned with and below a required position, inflating one or more bags on the support device to raise the battery pack thereon into a position in which it can be secured to the vehicle, the raising of the battery pack into contact with the vehicle, causing the support device to sink into contact with a supporting surface, and for removal of the battery pack, releasing the pack from the vehicle while the weight thereof is supported by the support device with the inflatable bag or bags inflated, then deflating the bag or bags, allowing the support device to rise on its cushion of air, and then manoeuvring the support device with the battery pack from beneath the vehicle.

2. A method as claimed in claim 1 in which there are valves for controlling the supply of air to the means for raising the support device and to the bag or bags, one of said valves being actuated to supply air to allow the support device to be moved on its cushion of air, but said one valve being closed to cut the supply off from the said means when the air bag or bags are inflated to carry the battery pack, further one or ones of said valves being actuated to admit to or exhaust air from the air bag or bags.

3. A method as claimed in claim 1 or claim 2 in which deflation of the bag or bags is accomplished by positively exhausting the air from it or from them.

4. A method as claimed in claim 3 in which the deflation of the bags is carried out by raising the support device to squash the bag or bags against the underside of the battery pack.

5. A method as claimed in claim 3 in which the deflation of the bag or bags is carried out by positive extraction of the air through an air compressor.

6. Apparatus for handling a battery pack for a battery powered vehicle, comprising a support device having means for raising the support device upon a cushion of air and at least one inflatable bag on the support device and on which a battery pack can be supported on the apparatus, the area of the support device subject to the air cushion and that in- contact with the bag or bags, when inflated, being so chosen that, when the battery pack is raised into contact, in use, with a vehicle to which it is to be fitted, the support device will sink into contact with a supporting surface.

7. Apparatus as claimed in claim 6, in which the support device is a platform with a handle whereby it can be manoeuvred when raised on a cushion of air.

8. Apparatus as claimed in claim 6 or claim 7 in which the support device has passages controlled by respective valves leading to a chamber beneath the device, to which air is supplied to raise the device, and to the or each bag.

9. Apparatus as claimed in claim 8 in which the valves are mounted in the support device and are actuatable from the side thereof, the valve in the passage leading to the chamber being capable qf occupying alternatively a position open to supply of air or a closed position and the or each valve to the bag or bags being capable of occupying a position open to supply of air, a closed position or an exhaust position.

1 0. Apparatus as claimed in any one of claims 6 - to 9 in which a portable compressor is provided to supply air under pressure to the apparatus.

11. Apparatus as claimed in claim 10 in which a quickly releasable coupling is provided between the compressor and the apparatus.

12. Apparatus as claimed in claim 11 wherein the coupling comprises a collar releasably connected to a member, whereby air can flow through them when connected together, and an over centre lever mechanism pivotally connected to the collar to permit quick separation of the collar from the member.

13. Apparatus as claimed in any one of claims 6 to 12 in which the bag or bags is or are connected to the support device through a connection in the centre region of the underneath surface of the bag or each bag, said connection serving also as the inlet and outlet for air to or from the bag or each bag.

14. Apparatus as claimed in any one of claims 6 to 1 3 including an inflatable skirt beneath which air for supporting the device can escape, the height of the skirt being adjusted by controlling air supply to the interior of the skirt.

1 5. Apparatus as claimed in any one of claims 6 to 14 wherein hand hold-openings are provided in the support device.

16. A method of handling a battery pack for a battery powered vehicle substantially as hereinbefore described with reference to and as shown in the accompanying drawings.

1 7. Apparatus for handling a battery pack for a battery powered vehicle substantially as hereinbefore described with reference to and as shown in the accompanying drawings.